Thick YSZ films prepared via a modified sol–gel route: Thickness control (8–80μm)

Dip-coated suspensions were used for preparing YSZ layers on both dense and porous substrates. The microstructure of the as-obtained thick films was studied by varying the characteristics of the organic YSZ suspensions (concentration, viscosity, etc.) used as coating bath. The thickness and the microstructure of the films were found to depend on the YSZ powder content and on the polymeric sol/dispersant solution (EtOH–MEK) ratio of the suspensions. The porosity created in the films depends on the rm ratio, e.g., the volume fraction of polymeric chains in the green layers. Finally, a comparison of the film thickness on dense and porous substrates showed that films prepared on porous substrates tend to exhibit higher thicknesses. Accordingly, YSZ ceramic films with thickness varying in between 8 and 80 μm were prepared.