Journal of Coating Technology and Innovation

This study investigates the microstructure and mechanical properties of Ceria-Yttria-Stabilized Zirconia (CYSZ) thermal barrier coatings (TBCs) with a NiCoCrAlY bond coat, fabricated using Atmospheric Plasma Spraying (APS) and Spark Plasma Sintering (SPS). TBCs play a vital role in high-temperature applications within the aerospace and automotive industries. APS coatings demonstrated greater porosity, increased thermally grown oxide (TGO) formation, and more significant thermal degradation at elevated temperatures. Conversely, SPS coatings were denser with superior adhesion, lower porosity, and enhanced mechanical properties, including higher microhardness. Phase analysis showed APS reduced CeO? content and transformed zirconia phases, while SPS preserved the original phase composition, ensuring better structural integrity and thermal stability. Overall, SPS outperformed APS in mechanical strength, phase stability, and oxidation resistance, making it a superior method for producing high-performance TBCs.

Magnetron sputtering is physical vapor deposition (PVD) process which is one type of vacuum deposition
method for development of thin films. In PVD, vapor of material mainly produced by two sources heating and
sputtering. This vapor material gets deposited on to the substrate material in the presence of vacuum. As magnetron
sputtering having different configuration is widely used in different researched area, attempt has been made to
provide detailed review of recent advancement in magnetron sputtering methods and it applications. Different
configurations of magnetron sputtering process such as closed field unbalanced magnetron sputtering (CFUBMS),
pulsed closed field magnetron sputtering (P-CFUBMS), high power impulse magnetron sputtering (HiPIMS) and
Deep oscillation magnetron sputtering (DOMS) are discussed. HiPIMS and DOMS are recently most researched
techniques for deposition of high quality and well adhered coatings. Process parameters affecting film deposition are
also listed in this paper. Majorly, this paper will outline recent applications of magnetron sputtering in Micro electro
mechanical systems (MEMS), lithium sulfur batteries, biomedical implants and instruments, supercapacitors,
tribology and many more for improvement of mechanical, optical, biomedical and electrical properties.