悬浮液等离子喷涂（SPS）解决了纳米尺度粉末输送困难的问题，在热喷涂领域得到了快速发展。介绍了悬浮液等离子喷涂的原理和特点，综述了不同工艺条件对热障涂层结构的影响：降低弧电压的波动可以提高SPS工艺的可控性；降低喷枪功率、降低悬浮液浓度、增大喷涂距离，可实现涂层由垂直裂纹结构向柱状晶结构的演变；降低表面粗糙度可提高柱状晶的均匀性；溶剂为乙醇、溶质粒度分布合理的悬浮液更容易获得柱状晶结构。总结了SPS制备热障涂层产生垂直裂纹结构和类柱状晶结构的机理，认为在相同表面粗糙度下，熔滴尺寸和切向速度是影响涂层结构的关键。SPS-8YSZ涂层的隔热性能和热循环性能较好，具有良好的应用前景。

Suspension plasma spray (SPS) technology develops quickly in the field of thermal spray due to solving the dif-ficulty of transporting nano-powders. The processing principles and characteristics of SPS were introduced and the effects of different processing parameters on the structure of SPS thermal barrier coatings were summarized. Decreasing the fluctuation of arc voltage could enhance the controllability of SPS processing, and lowering down the power of plasma torch and concentration of suspension and increasing spray distance could all achieve the evolvement of dense vertical crack structure to column-like structure. The homogeneity of columns could be enhanced by lowering down the surface roughness. Suspension with reasonable distribution of solute and ethanol as solvent was more likely to obtain a column-like structure. The deposition mechanism of SPS dense vertical crack coatings and column-like structure coatings was concluded. When the surface roughness is kept the same, size and tangential velocity of molten droplets are the key factors that impact the microstructure of coatings, while surface roughness influences column-like structure the most. SPS-8YSZ coating has a relatively good thermal insulation property and thermal cycling lifetime as well as a promising application.