Solution precursor high-velocity oxy-fuel spray ceramic coatings

For the first time, the solution precursor high-velocity oxy-fuel spray process was used to deposit Al2O3–ZrO2 ceramic coatings. X-ray diffraction analysis and transmission electron microscopy characterization show that the as-sprayed coating is composed of mixed nanocrystalline ZrO2 and γ-Al2O3 as well as amorphous phases. The as-sprayed coating consists of ultrafine splats with diameters ranging from 2 to 5 μm. Few spherical particles, hollow-shell structures are also observed on the coating surface. Polished cross-section shows that the coating is quite dense with a thickness of 40 μm.