Thin coatings on metallic substrates are extensively used in mechanical, aerospace, microelectronic, optical, and medical applications. Coatings affect the surface properties of the system, while bulk properties and strength primarily depend on the substrate. In coated components subjected to thermal cycling, differences in physical properties and chemical nature between constituent parts of co...

Yttria-stabilized zirconia (YSZ) has been used as a thermal/environmental barrier coating for gas turbine engine blades. Current methods of fabrication include air plasma spraying (APS) and electron-beam physical vapor deposition (EB-PVD). The APS technique results in a coating that loses effectiveness with thermal cycling. The EB-PVD technique deposits a columnar microstructure which accommoda...