Effect of the initial particle size distribution on the properties of suspension plasma sprayed Al2O3–TiO2 coatings

•Suspension feedstocks were prepared from nano- and submicron-size particles.•These suspensions were successfully deposited by suspension plasma spraying.•Mechanical properties were determined using nanoindentation technique.•Starting suspension characteristics have influence on the coating properties.

Al2O3–TiO2 coatings have been deposited by atmospheric plasma spraying from agglomerated, nanostructured powders showing better properties than those of their conventional (microstructured) counterparts. These nanostructured coatings can be also obtained by suspension plasma spraying however the research on suspension plasma sprayed Al2O3–TiO2 is still scarce. Consequently, it is crucial to study the effect of the suspension characteristics on the coating properties and to optimize the deposition process.In this work, Al2O3–13 wt.% TiO2 tribological coatings were successfully deposited by suspension plasma spraying from three different feedstocks: a nanometric suspension and two bimodal suspensions with different solid contents made up of titania nanoparticles and alumina submicron-sized particles. The coating microstructure and phase composition were characterized using scanning electron microscopy and X-ray diffraction analysis. Moreover, nanoindentation technique was used to determine the nanomechanical properties of coatings.The influence of the feed suspension characteristics on the final coating quality was analyzed. Findings showed that similar microstructures and phases were developed after depositing the different feedstocks. In addition suspension feedstock made up of nanoparticles resulted in a coating with better mechanical properties. However the use of submicron-sized particles in the suspension feedstocks gives rise to some technical and economic advantages in the process which should be taken into account when a suspension plasma spraying process is to be set up.