The present paper is addressed to the study of chemical stripping processes used in order to remove Thermal Spray deposited Thermal Barrier Coatings. Thermal Barrier Coatings consist in a bond coat of MCrAlY alloy (where M means for Ni, Co or a combination of both), that can be obtained generally by Vacuum Plasma Spray or High Velocity Oxygen Fuel and in a top coat of Yttria Partially Stabilized Zirconia obtained by Air Plasma Spray. These coatings are applied to gas turbine components in order to improve their hot corrosion and oxidation resistance and their service life time through a reduction of the service temperature. The paper focuses on the removal of NiCrAlY bond coat performed by chemical attack (based on hydrochloric acid). Characterization of the blade and vane surfaces after removal of NiCrAlY coatings has been performed from the point of view of surface morphology, metallurgical structure and chemical composition. The efficiency of the acid solution in NiCrAlY removal has been investigated and the behaviour of two Ni based alloys substrates in aggressive environment has been tested. The HCl based stripping solution shows good performances in Vacuum Plasma Sprayed NiCrAlY coatings removal from Ni superalloys. The tested stripping procedure is fast and safe because no damages to base materials have been noted.

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