A new type of Sm2Zr2O7 ceramic material has become a candidate material for thermal barrier coating because of its low thermal conductivity, high thermal expansion coefficient and good high temperature structure stability. In this paper, the effects of different process parameters on the morphology of ceramic powders were investigated. The spray drying technology was used to prepare Sm2Zr2O7 agglomerated powder. The micro morphology of Sm2Zr2O7 powder after granulation was observed by SEM. The effects of inlet temperature, pump creep rate on the characteristics of agglomerated powder were analyzed. At the same time, the effects of slurry properties on the micro characteristics of powder after granulation were discussed. The optimized Sm2Zr2O7 spray granulation process was determined as inlet temperature 175 ℃, pump creep rate 30% .
The orthogonal experiment with three factors and three levels was designed to control the process conditions in the thermal spraying process. The solid content, pH value and PVA addition on the stability and fluidity of sm2zr2o7 slurry at different levels were studied. The stability of sm2zr2o7 slurry was characterized by sedimentation experiment, and the fluidity of sm2zr2o7 slurry was detected by rheometer. It was determined that the solid content had the greatest influence on the properties of sm2zr2o7 slurry. The addition of PVA had the least effect. The optimized sm2zr2o7 slurry is as follows: solid content 50%, pH value 7 and PVA addition 4%.
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