Patent ID: 8283048

Claim:
A thermally sprayed coating made from a ceramic powder comprising ceramic powder particles, said ceramic powder particles comprising a yttria-stabilized zirconia component and a mullite-based component, wherein said ceramic powder particles contain from about 70 to about 95 percent by weight of the yttria-stabilized zirconia component, with the balance being the mullite-based component, wherein the average macro-particle size of the ceramic powder particles is from about 25 to about 75 microns, and wherein said ceramic powder particles comprise micronized sub-particles of the yttria-stabilized zirconia component and the mullite-based component, wherein the coating comprises a microstructure defined by islands of micronized mullite-based and yttria-stabilized zirconia composite particles, said islands partially melted and surrounded by a non-continuous phase of a completely melted mixture of said mullite-based component and said yttria-stabilized zirconia component, said melted mixture distributed throughout the coating.