This paper discusses the development of a two-layer thermal barrier coating that reduces heat flow to the lowest allowable level based on the temperature limits of the materials involved. The thick, porous coating was sprayed using a modified plasma torch and then thermally cycled until failure. Test results show that the process used to apply the bond coat has a measurable effect on the performance of the thermal barrier coatings. In addition to zirconia powders, a low cost polymer powder was used as well. Paper includes a German-language abstract.

This paper investigates the potential of graded and layered thermal barrier coating systems for high-temperature applications. It explains how the coatings are constructed from La 2 Zr 2 O 7 and YSZ layers and how their properties can be locally optimized to meet application needs. It examines the microstructure and evaluates the thermal performance of both single and multi-layer deposits. Paper includes a German-language abstract.

This paper demonstrates the use of an articulated robot in a plasma spraying operation for gas turbine transition ducts. A 3D model of the coating cell and workpiece plays a key role in the application, facilitating off-line programming and the verification of process parameters prior to spraying. In the spray experiments, a YSZ coating was applied to a NiCr bondcoat and subsequently characterized based on microstructure and hardness. The results were then used to set the injection parameters and travel path for the actual component. Paper includes a German-language abstract.

This paper presents and assesses a thermal spraying process for applying electrically insulating layers on glass ceramic substrates. It reviews the crystal structure of glass and glass ceramic and explains how it influences splat morphology, phase transformation, and the properties of plasma-sprayed materials. It is observed that substrate preheating is necessary with glass ceramics as is substrate cooling; the former to promote adhesion, the latter to control residual stress. Spray parameters such as plasma power and powder feed rate also have an effect on residual stress and must be controlled as well. Paper includes a German-language abstract.

In this paper, aramid and mullite light fiber fabrics are coated with different ceramics by atmospheric plasma spraying. To check the suitability of the process for as many technical applications as possible, different ceramic materials are used and multilayer coatings are produced as well. Test results for bioinert and biocatalytic materials, such as titanium dioxide and aluminum oxide, and bioactive hydroxyapatite show that the concept has good potential for a range of biomedical applications. Paper includes a German-language abstract.

In this paper, a quantitative model of the viscous behavior of two-phase particles hitting a substrate is used to optimize a plasma spraying process for silicon-nitride composite layers. The model is derived from the observed behavior of Si 3 N 4 -YAS (Y 2 O 3 -Al 2 O 3 -SiO 2 ) layers and provides a basis for further study of ceramic-matrix composite layers. Paper includes a German-language abstract.

Atmospheric plasma sprayed thermal barrier coatings have been used for years in manufacturing as well as revision and repair. This paper provides an overview of recent advancements in TBC technology and discusses the factors with the greatest impact on coating life, reliability, and performance. Paper includes a German-language abstract.