Microstructures of partially stabilized zirconia manufactured via hybrid plasma spray process

Air plasma spraying and in situ laser irradiation by diode laser processes were combined to modify structural characteristics of TBCs. Results show that in situ laser remelting induces: (i) the growth of a columnar dendritic structure, which is promising concerning the thermo-mechanical properties of the coating; (ii) no phase transition: the main phase still remains the metastable tetragonal (t′) phase after laser treatment; (iii) an increase of the porosity level due to the formation of large cracks (as shown by image analysis).