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<p>Suspension plasma spraying (SPS) is a thermal spray process with unique potential for producing finely structured, porous coatings for thermal barrier coating (TBC) applications. However, the complex link between plasma operating conditions and particle processing mechanisms presents significant challenges for optimizing the process and controlling the microstructure. Using an Axial III Plus torch, this study focuses on determining the effect of plasma parameters (argon, hydrogen, and nitrogen flow rates and the arc current), on the various stages of in-flight particle treatment, and how this affects the final coating architecture. The results demonstrate that the total gas flow rate primarily governs the initial fragmentation and solvent evaporation processes. In addition, the arc current and gas composition have a critical influence on the thermal and kinetic treatment of the particles, impacting the specific enthalpy and velocity of the plasma jet. The study identifies hydrogen as a particularly influential parameter due to its dual impact: it significantly enhances the plasma’s thermal conductivity while also lowering the plasma density, thus increasing gas velocity. This duality enables fine control of the coating morphology, ranging from porous columnar structures to dense architectures with vertical cracking, by adjusting the balance between thermal and kinetic energy inputs. A plasma process map correlating specific enthalpy and plasma jet velocity with resulting microstructures is proposed, providing a framework for process selection based on target coating properties. This tool could be especially valuable for tailoring microstructures in TBC systems, where thermal conductivity and strain tolerance are critically dependent on porosity and architecture. This work highlights the importance of a detailed understanding of the thermo-kinetic treatment of particles in SPS, offering practical guidelines for process optimization and advancing the design of high-performance coatings.</p> Graphical Abstract <p></p>

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Investigation of Effects of Plasma Parameters in Axial Suspension Plasma Spray on In-Flight Suspension Treatment and Thermal Barrier Coating Microstructure

  • 期刊论文

  • 发表日期：

    2026年3月5日

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  • Maxime Gaudin,
  • Simon Goutier,
  • Geoffroy Rivaud,
  • Aurélien Joulia,
  • Emilie Béchade,
  • Vincent Rat,
  • Alan Kéromnès

摘要

Suspension plasma spraying (SPS) is a thermal spray process with unique potential for producing finely structured, porous coatings for thermal barrier coating (TBC) applications. However, the complex link between plasma operating conditions and particle processing mechanisms presents significant challenges for optimizing the process and controlling the microstructure. Using an Axial III Plus torch, this study focuses on determining the effect of plasma parameters (argon, hydrogen, and nitrogen flow rates and the arc current), on the various stages of in-flight particle treatment, and how this affects the final coating architecture. The results demonstrate that the total gas flow rate primarily governs the initial fragmentation and solvent evaporation processes. In addition, the arc current and gas composition have a critical influence on the thermal and kinetic treatment of the particles, impacting the specific enthalpy and velocity of the plasma jet. The study identifies hydrogen as a particularly influential parameter due to its dual impact: it significantly enhances the plasma’s thermal conductivity while also lowering the plasma density, thus increasing gas velocity. This duality enables fine control of the coating morphology, ranging from porous columnar structures to dense architectures with vertical cracking, by adjusting the balance between thermal and kinetic energy inputs. A plasma process map correlating specific enthalpy and plasma jet velocity with resulting microstructures is proposed, providing a framework for process selection based on target coating properties. This tool could be especially valuable for tailoring microstructures in TBC systems, where thermal conductivity and strain tolerance are critically dependent on porosity and architecture. This work highlights the importance of a detailed understanding of the thermo-kinetic treatment of particles in SPS, offering practical guidelines for process optimization and advancing the design of high-performance coatings.

Graphical Abstract