The effects of different spray angles (90°, 85°, 80°) on the microstructure and mechanical properties of a Y₂O₃ coating layer prepared using the atmospheric plasma spray (APS) process were studied. The powders employed in this study had a spherical shape and included a cubic Y₂O₃ phase. The APS coating layer exhibited the same phase as the powders. Thickness values of the coating layers were 90°: 203.7 ± 8.5 μm, 85°: 196.4 ± 9.6 μm, and 80°: 208.8 ± 10.2 μm, and it was confirmed that the effect of the spray angle on the thickness was insignificant. The porosities were measured as 90°: 3.9 ± 0.85%, 85°: 11.4 ± 2.3%, and 80°: 12.7 ± 0.5%, and the surface roughness values were 90°: 5.9 ± 0.3 μm, 85°: 8.5 ± 1.1 μm, and 80°: 8.5 ± 0.4 μm. As the spray angle decreased, the porosity increased, but the surface roughness did not show a significant difference. Vickers hardness measurements revealed values of 90°: 369.2 ± 22.3, 85°: 315.8 ± 31.4, and 80°: 267.1 ± 45.1 HV. It was found that under the condition of a 90° angle with the lowest porosity exhibited the best hardness value. Based on the aforementioned results, an improved method for the APS Y₂O₃ coating layer was also discussed.

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A T-800 (Co-Mo-Cr) coating material is fabricated using Co-Mo-Cr powder feedstock and laser cladding. The microstructure and melted Al erosion properties of the laser-cladded T-800 coating material are investigated. The Al erosion properties of the HVOF-sprayed MoB-CoCr and bulk T-800 material are also examined and compared with the laser-cladded T-800 coating material. Co and lave phases (Co₂MoCr and Co₃Mo₂Si) are detected in both the lasercladded T-800 coating and the bulk T-800 materials. However, the sizes of the lave phases are measured as 7.9 μm and 60.6 μm for the laser-cladded and bulk T-800 materials, respectively. After the Al erosion tests, the erosion layer thicknesses of the three materials are measured as 91.50 μm (HVOF MoB-CoCr coating), 204.83 μm (laser cladded T-800), and 226.33 μm (bulk T-800). In the HVOF MoB-CoCr coating material, coarse cracks and delamination of the coating layer are observed. On the other hand, no cracks or local delamination of the coating layer are detected in the laser T-800 material even after the Al erosion test. Based on the above results, the authors discuss the appropriate material and process that could replace conventional bulk T-800 materials used as molten Al pots.