Vacuum plasma spray deposition of YSZ-NiO-Ni coatings at different Ar and H2 gas flow rates

► We examine NiO reduction and properties of vacuum plasma sprayed YSZ-NiO-Ni coatings. ► Ar and H2 gas flow rate was varied to get the different plasma spray conditions. ► YSZ, NiO powders were injected YSZ, NiO, Ni phases were identified in the coatings. ► Ni and NiO components tend to dominate in charge transport process in the coatings. ► Deposited three component YSZ-NiO-Ni coatings showed porous structures.