Microstructural dependency of thermal expansion and sintering shrinkage in plasma-sprayed zirconia coatings

► Thermal expansion of thin plasma-sprayed coating samples was accurately measured. ► Plasma-sprayed coatings had no microstructural dependency of thermal expansion. ► However, their sintering shrinkage was significantly sensitive to splat geometry. ► This structural dependency of sintering shrinkage was verified by a numerical model. ► Control of splat geometry is effective for obtaining a sintering-resistant coating.