This paper presents recent developments in thermal spray coating technology for thermal power plants. As for thermal barrier coatings for gas turbines, to accommodate the high gas temperatures required to improve thermal efficiency, a new ceramic topcoat material with low conductivity was developed. As for wear-resistant coatings for boiler parts, a C-Cr-Fe alloy coating was developed that is lower in cost than conventional chromium carbide cermet. Field tests of boiler parts show that the erosion wear rates of these coatings are as good or better than that of conventional cermet.

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