Composite thermal spray powder of oxides and non-oxides

A method of making a thermal spray powder, the method comprising:

• combining two or more component powders to form a composite powder,
• wherein each of the two or more component powders have different morphologies;
• wherein each of the two or more component powders consist of
• rare earth stabilized zirconia in an amount of from greater than 0 weight percent to 90 weight percent;
• an oxide selected from the group consisting of aluminum oxide, barium strontium aluminosilicate, calcium oxide, hafnium oxide, high entropy oxide, magnesium oxide, mullite, and silicon oxide, and
• a rare-earth oxide selected from the group consisting of Ce, Dy, Er, Eu, Gd, Hf, Ho, La, Nd, Lu, Pm, Pr, Sc, Sm, Tb, Tm, Y, Yb, and mixtures thereof;
• wherein the high entropy oxide comprises a matrix having at least three principal elements each constituting between 5 weight percent and 35 weight percent of the matrix;
• wherein at least one of the two or more component powders has a particle size range of from about 10 μm to about 180 μm;
• and
• wherein at least two of the two or more component powders are produced via different manufacturing process selected from the group consisting of agglomeration, agglomeration-and-sintering, fused-and-crushed, chemical cladding, physical cladding, and hollow oxide spherical powder (HOSP).