Abstract Hollow microspheres were prepared by a combination method of electro-spraying and non-solvent induced phase separation, using a slurry of polymer with Y2O3-stabilized ZrO2 powder (YSZ). Subsequent sintering was carried out to obtain porous hollow YSZ microspheres with proper strength aiming to be thermal spraying feedstock. The ESNP particle size and distribution strongly depended on the applied voltage of the electro-spraying process and the jet nozzle diameter. The YSZ microspheres always consisted of a thin spongy shell and highly porous interior structure. The microsphere size decreased from 1000 to 100 μm with increasing voltage (10–20 kV). The cone-jet mode of electrospray reached steady as the nozzle diameter varied from 0.5 to 0.8 mm. Compared with the coatings made from commercial hollow spherical powder, the coatings prepared by ESNP powder had enhanced resistance to sintering and exhibited a longer life than commercial spray powder. It has demonstrated that the ESNP method provides a versatile way to manipulate the microstructure of ceramic microspheres, and could been used to fabricate high performance thermal barrier coatings by plasma spraying.

中文翻译：

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电喷涂结合非溶剂诱导相分离法制备的空心陶瓷微球：一种有前景的热障涂层原料

摘要 使用含Y2O3 稳定的ZrO2 粉末(YSZ) 的聚合物浆液，通过电喷雾和非溶剂诱导相分离的组合方法制备中空微球。随后进行烧结以获得具有适当强度的多孔空心YSZ微球，旨在作为热喷涂原料。ESNP 的粒径和分布很大程度上取决于电喷雾过程的施加电压和喷嘴直径。YSZ 微球总是由薄的海绵壳和高度多孔的内部结构组成。随着电压的增加（10-20 kV），微球尺寸从 1000 μm 减小到 100 μm。当喷嘴直径从 0.5 到 0.8 mm 变化时，电喷雾的锥形喷射模式达到稳定。与市售中空球形粉末制成的涂料相比，由 ESNP 粉末制备的涂层具有更高的抗烧结性，并且比商业喷涂粉末具有更长的使用寿命。结果表明，ESNP 方法提供了一种操纵陶瓷微球微观结构的通用方法，可用于通过等离子喷涂制造高性能热障涂层。