Reactive Spraying of Ceramics

Phase I will develop a method of simultaneously making and plasma spraying ceramic powder to make ceramic coatings and near net shapes. Such a process will produce higher purity and density, and lower cost coatings and near net shapes than can be obtained with existing spray methods. The process will be based on the use of the Microwave Driven Plasma Sprayer (MDPS) that this firm is developing. In the proposed program we will modify and use the MDPS to demonstrate the production and spraying of fine grained stabilized zirconia in the MDPS, starting with zirconyl acetate and a stabilizer, both in liquid form. We will develop a method for producing ceramic coatings and near net shapes of higher quality at lower cost. The market for sprayed ceramic coatings is greater than or equal to $100 M/yr, with applications including thermal and wear barrier coatings on turbine blades, and near net shape components for high temperature operation.