Process optimization and innovative material applications gain more and more interest under the aspect of continuously increasing functional and structural demands on thermal sprayed coatings. With the cascaded triple arc plasma gun generation, the atmospheric plasma spraying process was advanced by delivering enhanced plasma stability and, associated with this, higher deposition efficiency. The TriplexPro 200 is the latest version of a three cathode plasma spraying system on the market and offers distinctly higher particle velocities, due to its advanced nozzle design. As a result of the higher particle velocities, lower particle oxidation and higher coating density can be realized. In order to increase the corrosion protection of metallic coatings and the thermal properties of TBCs, the aim of the work performed is a parametric study to deposit advanced coating systems for high temperature applications.

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