Role of process type and process conditions on phase content and physical properties of thermal sprayed TiO₂ coatings

Thermal spray represents an advantageous technique for depositing large-area titanium dioxide coatings that are of interest for both traditional wear-resistant coatings as well as functional applications such as photo-induced decontamination surfaces. Numerous past studies have examined the phase evolution and properties of TiO₂ coatings using different thermal spray processes or parameters. In this paper, an integrated study of thermal sprayed TiO₂ was conducted with different thermal spray devices and process parameters for a single feedstock powder comprising the metastable anatase phase. The aforementioned variables are correlated with in-flight particle state (particle temperature and velocity), phase evolution, and coating physical properties. The results are represented through the framework of process maps which connect process parameters with material properties. Based on the phase characterization, an initial exploration of the metastable phase evolution during thermal spray deposition of TiO₂ is proposed. Furthermore, the sprayed TiO₂ coatings show varying degrees of electrical conductivity associated with process-induced stoichiometric changes (vacancy generation) in the TiO₂. The effects of these stoichiometric changes as well as extrinsic microstructural attributes (pores, cracks, interfaces), contribute to the complex electrical response of the coatings. This integrated study provides insights into the process-microstructure-property relationship with the ultimate goal of tailoring the functionality of spray deposited oxide thick films.