The most recent increase in turbine entry temperature (TET) can be obtained by the use of Thermal Barrier Coatings (TBCs) on cooled hot section components. The TBC systems are comprised of Ni-based super-alloy substrate which provides certain mechanical properties and blade geometry consisting of a ceramic top coat with low thermal conductivity applied to a metallic bond coat resulting in a significant temperature drop across the coating. The bond coat provides oxidation resistance and adherence of the top coat to the substrate. In this study different bond coat layers were applied on carbon steel substrates which were covered by yttria stabilized zirconia (YSZ) as a top coat layer using atmospheric plasma spray technique (APS). Al-12%Si and Al 99% were deposited by cold gas dynamic spray technique (CGDS) while Ni-5%Al layer was deposited by high velocity oxy fuel technique (HVOF). Heat treatment was performed on the samples under controlled atmosphere for 15 hrs. The microstructure and micro hardness of as sprayed and after heat treatment samples were investigated. Adhesion strength for top coat / bond coat interface and bond coat / substrate interface were investigated. The residual stresses for as sprayed and after heat treatment was estimated by XRD measurement on the top coat layer with different bond coat material. The results indicate that the adhesion strength either for as sprayed or after heat treatment was enhanced using this new bond coat materials compared to the traditionally as deposited Ni Co Cr Al Y bond coat material.

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