Preparation of spherical Y2SiO5 powders for thermal-spray coating

Yttrium silicate, for its high oxidation resistance, is an important candidate for protective coating for carbon-fiber-reinforced composites at temperatures above 1600 °C. A novel method, consisting of co-precipitation, spray-drying, heat-treatment and plasma-densification, is developed to prepare Y2SiO5 powders for thermal-spraying. The composition, morphology and flowability of the synthesized Y2SiO5 powders are investigated by XRD, SEM and Hall Flowmeter, respectively. The results show that the synthesized Y2SiO5 powders are nearly spherical with high purity. The apparent density and flowability of the Y2SiO5 powders are 1.87 g/cm3 and 37 s/50 g, respectively, which lead to a high deposition efficiency of up to 80% for atmospheric plasma spraying.