Thermal barrier coatings (TBCs) consisting of a yttria-partially-stabilized zirconia (YSZ) topcoat and a metallic bond coat are used to protect components in high temperature environments such as the hot section of a gas turbine. In this study, the bond coats have been fabricated using different thermal spray processes, including vacuum arc spaying, high-velocity oxyfuel flame spraying, low-pressure plasma spraying, air plasma spraying, and detonation spraying. The microstructure of the resulting TBCs is characterized based on XRD, SEM, and TEM analysis and various properties are measured, including high-temperature oxidation, cohesion strength, thermal impact, and heat insulation temperature.

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