Preparation and Distribution Analysis of Thermal Barrier Coatings Deposited on Multiple Vanes by Plasma Spray-Physical Vapor Deposition Technology

The multicomponent NiCoCrAlTaY coating as bond layer as well as the zirconia stabilized by yttrium oxide (YSZ) coating as top ceramic layer was deposited on duplex vane surface by plasma spray-physical vapor deposition (PS-PVD) system. The thickness and microstructure of thermal barrier coatings (TBCs) under the influence of duplex vane geometry were presented in this article. It has been proven that the entire surface of duplex vane was covered by NiCoCrAlTaY and YSZ coatings. The position with thickest coating was found close to the leading edge and trailing edge of the vane. In those places, the coating was approximately 80–100% thicker than in the other areas on duplex vane. The obtained results indicate that it is possible to manufacture the TBCs including metallic bond layer and top ceramic layer by PS-PVD process on multiple vanes for gas turbines.