What method is used for measuring ZrO2 thermal sprayed coating?
Can you characterize the coated layer by XRD, AFM, measure the thickness and SEM, in addition to corrosion test to estimate the protection efficiency.
What has to be measured depends on the application:
in thermal barrier applications, you may measure coating thickness, porosity, morphology, hardness etc. on a polished cross section. The performance and long term reliability can be determined by a repeated thermal shock test in the relevant temperature regime (heat up on burner rig and cool down again by a cold air stream like in a gas turbine for aeroplanes) Scratch tests and adhesion tests are also necessary. To monitor the formation of TGO (thermally grown oxide) at the interface prolonged exposition to high temperature is necessary.
in SOFC application you would also test if the coating is gas tight, measure its ionic conductivity etc.
You can measure the coating thickness by optical microscopy in a polished cross section sample, and by image analysis you can count the quantity of porosity (% of area), many others characterization techniques can be used, depending on demand.
If you intend to measure the coating thickness using non destructive technique XRF will be the proper measuring method
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