Atmospheric plasma sprayed thermal barrier coatings with high segmentation crack densities: Spraying process, microstructure and thermal cycling behavior

► Fused and crushed YSZ as feedstock for APS thermal barrier coatings (TBCs). ► Optimization of spraying process to induce high segmentation crack densities. ► Improved TBCs with very high segmentation crack densities. ► Manufactured TBCs show promising thermal cycling performance.