Microstructural evolution of plasma sprayed submicron-/nano-zirconia-based thermal barrier coatings

- Dual-modal submicron-coating and multi-modal nano-coating were fabricated.
- Interface between recrystallization zone and unmelted nano-particles linked up.
- Content of unmelted nano-particles decreased from 13% to 7%.
- Multi-modal nano-coating has high-temperature instability.
- The submicron-coating showed a good thermal shock resistance.