Synthesis of Yttria-Stabilized Zirconia Particles by Flame Spray Pyrolysis Method

This paper presented a novel synthesis method for yttria-stabilized zirconia (YSZ) by using the flame spray pyrolysis (FSP) method. Spherical and dense YSZ particles for thermal barrier coating were successfully synthesized by FSP from the nebulized precursor solution. XRD results revealed that the YSZ powder is only composed of tetragonal phase particles. Most particles are a few hundred nanometers in diameter and their sizes are mainly dependent on the concentration of the precursor solution, while flame condition has little effect. Particle size and morphology are greatly affected by the precursor composition. Particles synthesized from ethanol precursor solution are more uniform and better-defined than those from aqueous solution.