Topographical and microstructural property relationships of plasma sprayed yttria stabilised zirconia coatings on complex surfaces

Understanding the process-property relationships of plasma sprayed ceramic coatings is key to expanding their use into current and future applications, allowing for greater operational and environmental efficiencies. This work developed methods to quantify the intricate surface topography of plasma sprayed yttria stabilised zirconia coatings deposited onto complex shaped geometries. New useful relationships were uncovered, including a correlation among surface topography, thickness and microstructure that will assist in the quality assessment of coatings applied to complex shapes. The overall understanding of these relationships will aid in the optimisation and enhanced efficiency for the predictable design of future coatings on complex surfaces.