A comparative study of the optical and microstructural properties of suspension and atmospheric plasma sprayed thermal barrier coatings

Thermal radiation is an increasingly important issue for thermal barrier coating (TBC) applications in aircraft engine components. As operating temperatures increase, the radiative part of the heat load increases significantly faster than the conductive portion; as such, TBCs may not be as efficient in protecting their underlying heat-sensitive metallic components. To address this issue, new coating morphologies must be investigated. In this study, we compare the optical performance of atmospheric plasma sprayed (APS) and suspension plasma sprayed (SPS) yttria-stabilized zirconia (YSZ) coatings. First, we extract their absorption and scattering coefficients from spectrophotometry measurements via the inverse adding-doubling (IAD) method. The microstructure of the coatings is then analyzed and compared using scanning electron microscopy (SEM) and mercury infiltration porosimetry (MIP). SPS samples are found to offer higher radiation blocking properties due to a more uniform distribution of pores with an average smaller pore diameter than the APS samples. This results in an overall higher pore density, with each pore interface acting as a scattering site, and therefore a higher propensity for scattering events.