Multi-scale pore morphology in directed vapor deposited yttria-stabilized zirconia coatings

A high pressure, electron-beam directed-vapor deposition process has been used to deposit partially stabilized zirconia containing 7% mass yttria at deposition pressures of 7.5–23 Pa. Anisotropic, ultra-small-angle X-ray scattering (USAXS) was then used to determine the surface area, shape and orientation of pores within the coatings. The total surface area of the ellipsoidal shaped pores was found to increase with deposition pressure. However, the through-thickness thermal conductivity measurements reveal the existence of a minimum thermal conductivity in coatings deposited at an intermediate pressure. Observations of the anisotropic X-ray scattering intensity at this intermediate pressure indicated greater proportions of both feather-like (oblate) pores with their major dimension at about 60° to the plane of the coating and fine columnar (prolate) pores oriented perpendicular to the coating plane. Since these oblate pore orientations are most efficient at impeding conductive thermal transport through the coating, it is believed that the change in preferred pore orientations with pressure is responsible for the higher thermal resistance of coatings grown in the intermediate pressure regime.