Patent ID: 7220497

Claim:
A yttria-coated ceramic component of a semiconductor material processing apparatus, comprising: a substrate comprising a ceramic material; a thermal-sprayed first yttria-containing coating on at least one surface of the substrate; and a bond layer comprising a multi-phase oxide including the ceramic material and yttria at an interface between the substrate and the first yttria-containing coating, the bond layer having been formed by co-sintering the substrate and the as-thermal sprayed first yttria-containing coating; wherein (i) the first yttria-containing coating includes an exposed surface that has been treated by a plasma conditioning treatment to reduce particles of yttria attached to the exposed surface after the co-sintering, or (ii) the component further comprises an as-thermal sprayed second yttria-containing coating on the sintered first yttria-containing coating and covering the particles of yttria attached to the exposed surface; and wherein when (i), the first yttria-containing coating has a porosity of less than about 20%, a crystal structure that is from about 95% to about 100% cubic, and a bond strength of from about 200 ksi to about 400 ksi; and when (ii), the first yttria-containing coating and the second yttria-containing coating have a porosity of less than about 20%, a crystal structure that is from about 95% to about 100% cubic, and a bond strength of from about 200 ksi to about 400 ksi.