Microstructures and Properties of Thermal Barrier Coatings Deposited by Hybrid Water-Stabilized Plasma Torch

This study demonstrates the applicability of water-stabilized plasma (WSP) spraying for producing thermal barrier coatings (TBCs). A hybrid WSP torch was used to deposit yttria-stabilized zirconia (YSZ) topcoats from powder, suspension, and solution feedstocks. A NiCrAlY bond coat was also sprayed and Hastelloy-X alloy was used as the substrate material. Microstructure, phase composition, and thermal cycle endurance were evaluated. All coatings showed excellent stability and thermal cycle endurance, withstanding more than 700 cycles, and in one case, more than 900 cycles.