A novel study about the synthesis of zirconia and calcia-stabilized zirconia powders were carried out by DC thermal plasma starting from cheap precursors as the carbonates. Different operational parameters were investigated to explore the effects of the process conditions, such as the plasma torch power and the gas flow rate on the composition and the morphology of the powders. The products phase changes from a metastable tetragonal to monoclinic/tetragonal mixture. Basically a main tetragonal phase was obtained at low torch power (7 kW) while the amount of monoclinic phase linearly rises with the power, up to 66 wt% at 26 kW of plasma power and high gas flow rate. The gas flow rate also affects the shape and the size of the powder, where high values reduce powder aggregation and enhance the spherical shape. The best results were achieved at 22 kW of plasma power and high gas flow rate, with powders of roundness about 79% and a wide particle size distribution. Adding the calcium carbonate to the zirconium carbonate (corresponding to 8 wt% CaO in the final mixture), the plasma treatment mainly produces a tetragonal phase zirconia, that at 1400 °C in furnace changes in a stable cubic phase. These powders could be made suitable for further industrial applications after proper treatments. © 2019, Springer Science+Business Media, LLC, part of Springer Nature.

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