This study presents the results of thermal cycling experiments on thermal barrier coatings deposited using hybrid water/argon-stabilized plasma (WSP-H) torches. Topcoats produced from YSZ suspensions and powders were successfully prepared and evaluated by thermal fatigue testing. Quad-layer coatings with topcoats consisting of yttria stabilized zirconia, gadolinium zirconate, and yttrium aluminum garnet were also prepared and tested at high temperatures and thermal gradients. The results obtained show the potential of WSP-H technology for applications where protection of large components or deposition of thick coatings are required.

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