Segmented thermal barrier coatings for ID and OD components using the SinplexPro plasma torch

Thermal barrier coatings (TBCs) with high thermal strain tolerance and erosion resistance have been applied onto the internal and external diameters of hot sections of gas turbine engine components. In this work, strain tolerant, segmented TBCs with a variety of crack densities and porosities were developed using the SinplexPro cascaded torch. Design of experiments were carried out to study the effect of process variables such as powder morphology, plasma power, spray distance, feeding rate etc on the particle in-flight behavior, coating microstructure and properties. Thermal cycle behavior and erosion resistance of these segmented TBCs, with various crack densities and porosities, were also evaluated. Examples of the application of SinplexPro erosion resistant and highly strain tolerant TBCs onto ID and OD engine components were demonstrated.