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Handbook of Advanced Ceramics and Composites pp 1–42Cite as

New Generation Ceramic Coatings for High-Temperature Applications by Liquid Feedstock Plasma Spraying

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Abstract

Plasma spraying with liquid feedstock offers an exciting opportunity to obtain coatings with characteristics that are vastly different from those produced using conventional spray-grade powders. The two extensively investigated variants of this technique are suspension plasma spraying (SPS), which utilizes a suspension of fine powders in an appropriate medium, and solution precursor plasma spraying (SPPS), which involves use of a suitable solution precursor that can form the desired particles in situ. The advent of axial injection plasma spray systems in recent times has also eliminated concerns regarding low deposition rates/efficiencies associated with liquid feedstock. The 10–100 μm size particles that constitute conventional spray powders lead to individual splats that are more than an order of magnitude larger compared to those resulting from the fine (approximately 100 nm–2 μm in size) particles already present in suspensions in SPS or formed in situ in SPPS. The distinct characteristics of the resulting coatings are directly attributable to the above very dissimilar splats (“building blocks” for coatings) responsible for their formation. This chapter discusses the salient features associated with SPS and SPPS processing, highlights their versatility for depositing a vast range of ceramic coatings with diverse functional attributes, and discusses their utility, particularly for high-temperature applications through some illustrative examples. A further extension of liquid feedstock plasma processing to enable use of hybrid powder-liquid combinations for plasma spraying is also discussed. This presents a novel approach to explore new material combinations, create various function-dependent coating architectures with multi-scale features, and enable convenient realization of layered, composite, and graded coatings as demonstrated through specific examples.

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Authors and Affiliations

  1. University West, Trollhättan, Sweden

    S. Joshi, N. Markocsan & P. Nylén

  2. International Advanced Research Centre for Powder Metallurgy & New Materials (ARCI), Hyderabad, India

    G. Sivakumar

Authors
  1. S. Joshi
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  2. N. Markocsan
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  3. P. Nylén
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  4. G. Sivakumar
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Corresponding author

Correspondence to S. Joshi .

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Editors and Affiliations

  1. ARCI, International Advanced Research Centre f ARCI, Hyderabad, India

    Yashwant Mahajan

  2. ARCI, International Advanced Research Centre f ARCI, Hyderabad, Telangana, India

    Johnson Roy

Section Editor information

  1. International Advanced Research Centre for Powder Metallurgy and New Materials, Balapur, Hyderabad, India

    L. Rama Krishna

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Joshi, S., Markocsan, N., Nylén, P., Sivakumar, G. (2020). New Generation Ceramic Coatings for High-Temperature Applications by Liquid Feedstock Plasma Spraying. In: Mahajan, Y., Roy, J. (eds) Handbook of Advanced Ceramics and Composites. Springer, Cham. https://doi.org/10.1007/978-3-319-73255-8_48-1

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  • DOI: https://doi.org/10.1007/978-3-319-73255-8_48-1

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  • Print ISBN: 978-3-319-73255-8

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