Abstract: There is provided a method for depositing a TiO2—Cr2O3 ceramic coating on a substrate. The method includes mixing a powder of sprayable nanostructured titanium(IV) oxide (n-TiO2) and a powder of chromium(III) oxide (Cr2O3), thereby obtaining a n-TiO2—Cr2O3 powder blend. The method also includes thermal spraying particles of the n-TiO2—Cr2O3 powder blend on the substrate at an in-flight particle temperature of or greater than 2350° C. and a particle in-flight velocity of or greater than 350 m/s, thereby obtaining a coated substrate.

Abstract: There is provided a method for depositing a TiO2-Cr2O3 ceramic coating on a substrate. The method includes mixing a powder of sprayable nanostructured titanium(IV) oxide (n-TiO2) and a powder of chromium(III) oxide (Cr2O3), thereby obtaining a n-TiO2-Cr2O3 powder blend. The method also includes thermal spraying particles of the n-TiO2-Cr2O3 powder blend on the substrate at an in-flight particle temperature of or greater than 2350° C. and a particle in-flight velocity of or greater than 350 m/s, thereby obtaining a coated substrate.

Abstract: By engineering thermal spray parameters, such as temperature and velocity, and engineering feedstock powder size and morphology, ceramic coatings may be produced having desired mechanical and thermal properties. The ceramic thermal spray coating may have a microstructure having about 10-80% by cross-sectional area of a particulate phase based on, surface area of the coating, and the particulate phase is uniformly distributed throughout the coating. The particulate phase is an unmelted portion of the thermal sprayed feedstock, which is highly porous and may be produced by agglomerating nanoparticles of the ceramic. Such coatings can be applied as TBCs or as abradable coatings.

Abstract: By engineering thermal spray parameters, such as temperature and velocity, and engineering feedstock powder size and morphology, ceramic coatings may be produced having desired mechanical and thermal properties. The ceramic thermal spray coating may have a microstructure having about 10-80% by cross-sectional area of a particulate phase based on, surface area of the coating, and the particulate phase is uniformly distributed throughout the coating. The particulate phase is an unmelted portion of the thermal sprayed feedstock, which is highly porous and may be produced by agglomerating nanoparticles of the ceramic. Such coatings can be applied as TBCs or as abradable coatings.

Abstract: By engineering thermal spray parameters, such as temperature and velocity, and engineering feedstock powder size and morphology, ceramic coatings may be produced having desired mechanical and thermal properties. The ceramic thermal spray coating may have a microstructure having about 10-80% by cross-sectional area of a particulate phase based on surface area of the coating, and the particulate phase is uniformly distributed throughout the coating. The particulate phase is an unmelted portion of the thermal sprayed feedstock, which is highly porous and may be produced by agglomerating nanoparticles of the ceramic. Such coatings can be applied as TBCs or as abradable coatings.