Segmented thermal barrier coatings produced by atmospheric plasma spraying hollow powders

Segmented thermal barrier coatings were produced by plasma spraying hollow and solid ZrO2–8 wt.% Y2O3 powders. The solid powder (SP) had greater capability of producing segmentation cracks in coating compared with the hollow powder (HP). High substrate temperature (Ts) gave rise to an increased segmentation crack density (Ds). The segmentation crack network was still stable even after sintering at 1300 °C for 15 h. The microcracks that are mainly attributed to delaminations between splats had a negative effect on the origin and propagation of segmentation cracks.