Characterization of Thermal Barrier Coatings Produced using a Novel Atmospheric Plasma Spray Torch

Abstract This article describes the development and evaluation of a novel atmospheric plasma spray torch designed to overcome limitations in coating internal diameter surfaces. A case study demonstrates the torch's effectiveness in producing high-quality thermal barrier coatings (TBCs) for turbine components, applying NiCoCrAlY+HfSi bond coats and 8 wt% YSZ topcoats with appropriate porosity levels. Analysis results confirm that this torch delivers comparable performance to conventional torches while enabling the critical capability of operating in confined geometries, addressing a significant gap in thermal spray applications for gas turbine engine components subjected to extreme operating conditions.