Thermal barrier coatings (TBCs) with segmented or cracked microstructures exhibit enhanced thermal cyclic behavior and erosion resistance, along with improved application economics, over conventional TBCs.

This case study addresses the use of online diagnostic tools to adjust spray parameters to ensure consistent results.

This case study reviews the considerations in applying plasma spray thermal barrier coatings on augmenters used in military aircraft turbine engines to extend their service life.

One of the most recent success stories for thermal spray in the automotive industry involves the development of plasma transferred wire arc (PTWA) for aluminum engine blocks. Driven by the demand to increase fuel efficiency, automakers are placing emphasis on decreasing overall vehicle weight as well as improving engine efficiency by reducing internal friction losses. The surface structure of the composite coating created by the PTWA process promotes favorable lubrication, low friction, wear resistance, improved heat transfer, and decreased bore distortion in engine block cylinders.

This article describes the design and operation of a high-deposition rate plasma nozzle developed for ambient pressure spraying.