Thermal barrier coatings (TBCs) are widely utilized in gas turbine engines for power generation. In recent years, the application of TBCs in automotive has been introduced to improve engine efficiency. Low thermal conductivity and high durability are desired coating properties for both gas turbine engines and automotive. Also, suspension plasma spraying (SPS) permits a columnar microstructure that combines both properties. However, it can be challenging to deposit a uniform columnar microstructure on a complex geometry, such as a gas turbine component or piston head, and achieve similar coating characteristics on all surfaces. This work's objective was to investigate the influence of spray angle on the microstructure and lifetime of TBCs produced by SPS. For this purpose, SPS TBCs were deposited on specimens using different spray angles. The microstructures of the coatings were analyzed by image analysis for thickness, porosity, and column density. Thermal and optical properties were evaluated on each TBC. Lifetime tests, specifically designed for the two applications, were performed on all investigated TBCs. The lifetime results were analyzed with respect to the TBC microstructure and thermal and optical properties. This investigation showed that there is a limit to the spray angle that achieves the best compromise between TBC microstructure, thermal properties, optical properties, and lifetime.

热障涂层 (TBC) 广泛用于发电的燃气涡轮发动机中。近年来，TBC在汽车中的应用被引入以提高发动机效率。低导热性和高耐久性是燃气涡轮发动机和汽车所需的涂层特性。此外，悬浮等离子喷涂 (SPS) 允许结合两种特性的柱状微观结构。然而，在复杂的几何形状（例如燃气轮机部件或活塞头）上沉积均匀的柱状微结构并在所有表面上实现相似的涂层特性可能具有挑战性。这项工作的目的是研究喷射角度对 SPS 生产的 TBC 的微观结构和寿命的影响。为此，使用不同的喷射角度将 SPS TBC 沉积在样品上。通过对厚度、孔隙率和柱密度的图像分析来分析涂层的微观结构。在每个 TBC 上评估热和光学特性。对所有研究的 TBC 进行了专门为这两种应用设计的寿命测试。对 TBC 微观结构以及热和光学性质的寿命结果进行了分析。这项研究表明，在 TBC 微观结构、热性能、光学性能和寿命之间实现最佳折衷的喷射角度存在限制。对 TBC 微观结构以及热和光学性质的寿命结果进行了分析。这项研究表明，在 TBC 微观结构、热性能、光学性能和寿命之间实现最佳折衷的喷射角度存在限制。对 TBC 微观结构以及热和光学性质的寿命结果进行了分析。这项研究表明，在 TBC 微观结构、热性能、光学性能和寿命之间实现最佳折衷的喷射角度存在限制。