Abstract:To alter the structure of thermal barrier coatings and enhance their high-temperature performance, this study prepared rare-earth-modified zirconia (GYYZ) agglomerated powder using solid-phase synthesis and spray drying methods, and regulated the structure of the GYYZ powder through inductive plasma spheroidization (IPS) technology. Scanning electron microscopy (SEM) analysis methods were used to characterize the surface morphology and internal microstructure of both conventional agglomerated powder and spheroidized powder. The results showed that, compared to the agglomerated GYYZ powder, the IPS-GYYZ powder consisted of a dense outer shell and a porous inner core. In addition, coatings were prepared using IPS-GYYZ powder and agglomerated GYYZ powder, and the IPS-GYYZ coatings exhibited better resistance to thermal shock cycling.