On the development of plasma-sprayed thermal barrier coatings

Various zirconate coatings were prepared on bare Nimonic-75 and on CoCrAlY bond coat by plasma spraying. The cyclic oxidation and hotcorrosion resistance of these coatings have been evluated. The wide difference in the properties of these coatings has been rationalized in terms of the thermal expansion mismatch between the coating and the substrate. On continued thermal cycling and in presence of molten salt, the life-limiting factor has been identified to be oxidation of the bond coat. The interconnected porosity in the ceramic coating is mainly responsible for such oxidation, and controlling this porosity would lead to life improvement.