Yttria-stabilized zirconia(YSZ)based thermal barrier coatings(TBCs)are deposited by high efficiency supersonic atmospheric plasma spraying(SAPS)system. The phase change time in heating and melting of the particles in SAPS process is analytically gained with Green's function method
which gets relatively close to the experimental data. And the moving process of solid-liquid interface within a particle is clearly revealed. The heating and melting process is numerically simulated
and the effect of initial temperature on particle melting rate is observed. Pre-heating before spraying can accelerate melting. The melting time of the particle can be shortened and the flattening degree can be increased by reducing the particle radius. The particle radius can be controlled by sifting to fabricate a fine and compact structure with columnar grains.
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