Parametric Analysis and Modeling for the Porosity Prediction in Suspension Plasma-Sprayed Coatings

  • Yongli ZhaoEmail author
  • Yan Wang
  • François Peyraut
  • Marie-Pierre Planche
  • Jan Ilavsky
  • Hanlin Liao
  • Ghislain Montavon
  • Audrey Lasalle
  • Alain Allimant
Peer Reviewed


The porous architecture of suspension plasma-sprayed coatings has a significant influence on the coating performances and thus should be properly designed for the intended applications. In this study, YSZ coatings were manufactured by suspension plasma spray (SPS), and a parametric study was performed with five different process parameters: suspension mass load, original powder particle size, substrate surface topology, spray distance, and spray step. Afterward, the porosity of the as-prepared coatings was investigated by imaging and x-ray transmission technique. A multivariate analysis on the collected experimental data was carried out. The results indicated that: (1) The total porosity of SPS coatings increases with the decrease in suspension mass load, while it shows the opposite trend by decreasing the spray distance, original powder particle size, substrate roughness, and spray step; (2) The main factor affecting coating total porosity is spray distance. Finally, a predictive model for coating total porosity was developed and was verified by experiments. Control of total porosity by using the predictive model was presented and explained as well.


Multivariate analysis Porosity Predictive model Process parameter Suspension plasma spray 



This research used resources of the Advanced Photon Source, a U.S. Department of Energy (DOE) Office of Science User Facility operated for the DOE Office of Science by Argonne National Laboratory under Contract No. DE-AC02-06CH11357. This research was also sponsored by startup research foundation of Shanghai University of Engineering Science No. 201980.


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Copyright information

© ASM International 2019

Authors and Affiliations

  • Yongli Zhao
    • 1
    • 2
    Email author
  • Yan Wang
    • 2
  • François Peyraut
    • 2
  • Marie-Pierre Planche
    • 2
  • Jan Ilavsky
    • 3
  • Hanlin Liao
    • 2
  • Ghislain Montavon
    • 2
  • Audrey Lasalle
    • 4
  • Alain Allimant
    • 4
  1. 1.School of Mechanical and Automotive EngineeringShanghai University of Engineering ScienceShanghaiChina
  2. 2.ICB, UMR 6303, CNRSUniversité de Bourgogne Franche-Comté, UTBMBelfortFrance
  3. 3.Advanced Photon Source, Argonne National LaboratoryArgonneUSA
  4. 4.Saint-Gobain CREECavaillonFrance

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