Effect of in-flight particle characteristics on the coating properties of atmospheric plasma-sprayed 8 mol% Y2O3–ZrO2 electrolyte coating studying by artificial neural networks

In-flight particle characteristics (surface temperature and velocity upon impact) are among the most important parameters which influence the coating microstructures and properties in atmospheric plasma spraying (APS) process. The purpose of this paper is to study hydrogen fraction used as secondary plasma forming gas on the in-flight particle surface temperature and by extension on the coating microstructures of atmospheric plasma-sprayed 8 mol% yttria stabilized zirconia electrolyte coatings implementing in particular artificial neural networks (ANN). Then, the predicted in-flight particle characteristics were on the one hand compared to experimental values and on the other hand correlated to some of the coating structural attributes (porosity and gas specific permeability). The predicted results were in good accordance with the experimental data. Results showed that the H2 flow rate had obvious influence on particle temperature and had almost no significant effect on particle velocity. Increasing the particle temperatures induced dense coating microstructure and improved the gas-tightness performance.