Magnesia-stabilised zirconia (MgO-ZrO2) is a spray-grade ceramic powder engineered for thermal spray deposition of thermal barrier coatings (TBCs) and wear-resistant ceramic layers. Formulated at approximately 20-25 wt% MgO, this composite locks a substantial fraction of the zirconia into a non-transformable cubic-plus-tetragonal microstructure with dispersed periclase, resisting the destructive phase transformation that plagues undoped zirconia under thermal cycling. Produced primarily by fusing and crushing to a blocky, angular morphology, the powder is built for consistent hopper flow and predictable melting in air plasma spray (APS) equipment. It is the same class of material that protected turbine blades, combustor liners, and hot-section hardware for decades before yttria-stabilized zirconia became the industry default, and it remains a proven, cost-effective choice for cost-sensitive and legacy-match thermal spray programs today. Custom particle size cuts, MgO loadings, and packaging are available for OEM and MRO qualification work.
Introduction to Magnesia-Stabilized Zirconia Powder
Magnesia-Stabilized Zirconia (MgO–ZrO₂) is a partially stabilised zirconia system containing approximately 20–25 wt% MgO, producing a multiphase microstructure of cubic zirconia, tetragonal zirconia precipitates, and residual periclase (MgO). Mg²⁺ substitution for Zr⁴⁺ generates oxygen vacancies that stabilise the zirconia phases and suppress destructive volume changes associated with the monoclinic–tetragonal transformation. Unlike lower-MgO structural Mg-PSZ, this higher-magnesia composition is optimised for thermal-spray coatings, balancing phase stability with low thermal conductivity. Fused-and-crushed powder is typically supplied in controlled sieve cuts, often around 11–74 µm with a D50 of 40–60 µm. Air plasma spraying produces porous, lamellar coatings for thermal barriers and high-temperature wear protection.
Answer: The composites of magnesium oxide and zirconia combine magnesium oxide's high thermal stability, strength, and insulation with zirconia's hardness and biocompatibility, producing materials that are especially effective under high temperatures and very demanding conditions.
Answer: Method of synthesis of magnesium oxide and zirconia composites: sol-gel processing, co-precipitation, solid-state reactions, or by chemical vapor deposition, depending upon the desired properties and applications.
Answer: Yes, zirconia is known for its excellent biocompatibility; therefore, the composites of the MgO/ZrO₂ system might be applied in dental and biomedical fields.
Answer: The standard grade runs a D50 of roughly 40-60 µm within a commercial sieve cut of about 11-74 µm. Finer cuts (~15-45 µm) suit thinner, smoother coatings, while coarser cuts (~45-75 µm) support thicker builds and higher deposition rates; custom cuts are available on request.
Introduction to Magnesia-Stabilized Zirconia Powder
Magnesia-Stabilized Zirconia (MgO–ZrO₂) is a partially stabilised zirconia system containing approximately 20–25 wt% MgO, producing a multiphase microstructure of cubic zirconia, tetragonal zirconia precipitates, and residual periclase (MgO). Mg²⁺ substitution for Zr⁴⁺ generates oxygen vacancies that stabilise the zirconia phases and suppress destructive volume changes associated with the monoclinic–tetragonal transformation. Unlike lower-MgO structural Mg-PSZ, this higher-magnesia composition is optimised for thermal-spray coatings, balancing phase stability with low thermal conductivity. Fused-and-crushed powder is typically supplied in controlled sieve cuts, often around 11–74 µm with a D50 of 40–60 µm. Air plasma spraying produces porous, lamellar coatings for thermal barriers and high-temperature wear protection.
Key Properties of Magnesia-Stabilized Zirconia Powder
Property
Value
Significance
Composition
~20-25 wt% MgO, balance ZrO2 (commercial thermal-spray grades commonly cluster around 20% or 24% MgO)
Sets phase-stabilisation level and the thermal/mechanical balance of the sprayed coating
CAS Number(s)
1314-23-4 (ZrO2); 1309-48-4 (MgO)
No unified CAS exists because the product is a two-oxide physical blend, not a single registered compound
Crystal structure/phase
Cubic + tetragonal ZrO2 matrix with dispersed periclase (MgO) precipitates
Two-phase microstructure suppresses the destructive monoclinic transformation and adds some toughening
Controls flowability, in-flight melting, and deposition efficiency in APS guns
Thermal conductivity (coating)
~1.0-1.5 W/m·K
Low conductivity is the core insulating function of a thermal barrier coating
Coating hardness
~300-450 HV (0.05-0.3 kgf)
Indicates the wear resistance of the deposited coating in abrasive/erosive service
Types & Grades of Magnesia-Stabilized Zirconia Powder
Magnesia-Stabilized Zirconia powder is offered in standard catalogue grades and particle size distributions, with custom purity, morphology, and packaging available for OEM and R&D use.
Higher magnesia loading used in plasma-spray research and coatings needing greater phase-stability margin
Fine-cut MSZ (~15-45 µm)
99% – 99.8%
Finer particle size for thinner, smoother coatings and finer as-sprayed microstructure
Coarse-cut MSZ (~45-75 µm)
99% – 99.8%
Higher deposition rate for thicker wear-resistant coating builds
High-purity electronic/insulator grade
99.9%+
Tightly controlled trace impurities for spark-plug insulator and ceramic substrate applications
Applications of Magnesia-Stabilized Zirconia Powder
Magnesia-Stabilized Zirconia powder supports demanding roles across research and production applications where this material’s specific structural, electronic, magnetic, or electrochemical properties are the key requirement.
Industry
Application
Function
Aerospace/gas turbines
Thermal barrier coatings on combustor and hot-section components
Insulates the metal substrate from combustion-gas heat, extending hot-section component life
Power generation
TBCs on land-based industrial gas turbine hardware
Reduces metal temperature and thermal fatigue under continuous-duty cycling
Industrial machinery
Wear-resistant coatings on pumps, valves, and rotors
Provides a hard, erosion- and abrasion-resistant working surface
Cutting tools
Thermal spray coatings on tool substrates
Improves hot hardness and wear life at the cutting edge
Electronics/insulators
Ceramic substrates and spark plug insulators
Combines high electrical resistivity with thermal and chemical stability
Refractories
Refractory linings and kiln furniture
Maintains dimensional and chemical stability under severe high-temperature service
Why Partner with Infinita Materials?
Technical Depth: in-house quality control with ICP-MS and XRF purity verification, particle size distribution and density measurement, and full certificates of analysis on every lot.
Global Logistics: reliable supply from single R&D-scale quantities to production-line volumes, with established international shipping.
Responsive Support: direct access to materials engineers for grade, particle size, and packaging selection, and process-compatibility questions.
Take the Next Step
Infinita Materials manufactures Magnesia-Stabilized Zirconia powder engineered to the purity, particle size, and morphology your process requires. Whether the requirement is a standard catalogue grade or a custom particle size distribution, purity, or packaging format, our team can help match the right specification to your process. Request a quote or speak with our technical team to discuss your material specification.
Other Related Product to Magnesium Oxide/ Zirconia
The composites of magnesium oxide and zirconia combine magnesium oxide's high thermal stability, strength, and insulation with zirconia's hardness and biocompatibility, producing materials that are especially effective under high temperatures and very demanding conditions.
Method of synthesis of magnesium oxide and zirconia composites: sol-gel processing, co-precipitation, solid-state reactions, or by chemical vapor deposition, depending upon the desired properties and applications.
Yes, zirconia is known for its excellent biocompatibility; therefore, the composites of the MgO/ZrO₂ system might be applied in dental and biomedical fields.
The standard grade runs a D50 of roughly 40-60 µm within a commercial sieve cut of about 11-74 µm. Finer cuts (~15-45 µm) suit thinner, smoother coatings, while coarser cuts (~45-75 µm) support thicker builds and higher deposition rates; custom cuts are available on request.
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