Reviewed Papers

Journal of Thermal Spray Technology

, Volume 15, Issue 4, pp 701-707

First online:

Plasma spray synthesis from precursors: Progress, issues, and considerations

  • B. G. RaviAffiliated withDepartment of Materials Science and Engineering, Center for Thermal Spray Research Email author 
  • , S. SampathAffiliated withDepartment of Materials Science and Engineering, Center for Thermal Spray Research
  • , R. GambinoAffiliated withDepartment of Materials Science and Engineering, Center for Thermal Spray Research
  • , J. B. PariseAffiliated withDepartment of Geosciences and Chemistry, State University of New York
  • , P. S. DeviAffiliated withElectroceramics Division, Central Glass and Ceramic Research Institute

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Precursor plasma spray synthesis is an innovative and rapid method for making functional oxide ceramic coatings by starting from solution precursors and directly producing inorganic films. This emerging method utilizes molecularly mixed precursor liquids, which essentially avoids the handling and selection of powders, opening up new avenues for developing compositionally complex functional oxide coatings. Precursor plasma spray also offers excellent opportunities for exploring the nonequilibrium phase evolution during plasma spraying of multicomponent oxides from inorganic precursors. Although there have been efforts in this area since the 1980s and early 1990s with the goal of synthesizing nanoparticles, only recently has the work progressed in the area of functional systems. At the Center for Thermal Spray Research an integrated investigative strategy has been used to explore the benefits and limits of this synthesis strategy. Water- and alcohol-based sol/solution precursors derived from various chemical synthesis methods were used as feedstocks to deposit thin/thick films of spherical and nanostructured coatings of yttrium aluminum garnet (YAG), yttrium iron garnet, lanthanum strontium manganate and Zr-substituted yttrium titanates, and compositions of Y2O3-Al2O3 and their microstructural space centered around stoichiometric YAG. A detailed discussion of the salient features of the radiofrequency induction plasma spraying approach, the results obtained in the investigations to develop various functional oxide coatings, and process issues and challenges are presented.


ceramic coatings liquid precursor luminescent coatings magnetic properties microstructure thermal plasma spraying