The Development and Characterization of Novel Yttria-Stabilized Zirconia Coatings Deposited by Very Low Pressure Plasma Spray

   Very low pressure plasma spray (VLPPS) was used for the liquid and vapor deposition of yttria-stabilized zirconia (YSZ) as a potential manufacturing method for solid oxide fuel cell (SOFC) electrolytes. Coatings created by liquid deposition had a microstructure consisting of dense splats. Vapor deposited coatings had a columnar microstructure similar to coatings deposited by electron beam physical vapor deposition EB-PVD). The columnar microstructure was dependent on substrate temperature and vapor flux continuity. Microstructures consisting of layers of splats and columns were also observed. Coating microstructure was analyzed using X-ray diffraction (XRD) and scanning electron microscopy (SEM). Electrical conductivity was measured using a four-wire direct current method.