Characterization of yttria-stabilized zirconia coatings deposited on AA2024-T351 aluminum alloy by air plasma spraying is carried out in the present work to assess its applicability as a thermal barrier coating on automotive components aluminum alloys. Tetragonality of coating microstructures was confirmed through X-ray diffractometer, transmission electron microscopy, and high-resolution transmission electron microscopy. Lattice-image spacing obtained from high-resolution transmission electron microscopy confirmed multilayer structure of the coating and that the tetragonal phases are stable. From the optical microscopy it was found that there are good coating particle distribution and homogeneity of coating particles on the substrate while atomic force microscopy provided information about surface bumps and pits. Small roughness of the coating microstructure was found to be very low. Small roughness showed good deposition efficiency of the coating structures.
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