Disclosed herein is a method for applying
plasma-resistant coatings for use in
semiconductor processing apparatus. The coatings are applied over a substrate which typically comprises an aluminum
alloy of the 2000 series or the 5000 through 7000 series. The
coating typically comprises an
oxide or a
fluoride of Y, Sc, La, Ce, Eu, Dy, or the like, or
yttrium-aluminum-garnet (YAG). The
coating may further comprise about 20 volume % or less of Al2O3. The coatings are typically applied to a surface of an aluminum
alloy substrate or an anodized aluminum
alloy substrate using a technique selected from the group consisting of thermal /
flame spraying,
plasma spraying,
sputtering, and
chemical vapor deposition (CVD). To provide the desired
corrosion resistance, it is necessary to place the
coating in compression. This is accomplished by controlling deposition conditions during application of the coating.