Investigation of parameters' effect on segmentation cracks formation in Zirconia coating

The thermal barrier coatings with segmentation cracks have been proved with excellent thermal shock resistance property, but it is unclear that how the spray parameters affect the initiation of segmentation cracks. In order to find the relationship, orthogonal design experiments were used to analyze the effect of parameters, including spray distance, transfer speed, and powder feedrate. It is found that the descending order of parameters according their effect on the formation of segmentation cracks is: spray distance, feedrate, and the transfer speed. Furthermore, the parameters for getting high segmentation crack density are: spray distance is 55mm, feedrate is 2.5RPM and transfer speed is 100mm/s.