In this line-of-sight process that is carried out in an open atmosphere, a high-powered jet of ionized argon and/or helium or hydrogen (plasma) melts ceramic powders and other high-temperature materials. The molten particles are then sprayed on a carefully cleaned and prepared surface.

Applications of APS

  • APS renders porous coatings and is only suitable for materials that tolerate brief exposure to atmospheric conditions 
  • Used to spray hard facing materials and other build-up materials in less demanding applications, thus offering a more economical alternative to High Velocity Oxygen Fuel (HVOF) spraying 
  • Mainly used to spray Thermal Barrier Coatings (TBC) on turbine components of any size 
  • Also for application of chromium carbide hardfacing coatings for better fretting resistance on combustion parts

TBC coatings

  • APS TBC coatings require careful cleaning immediately before the application of the (metallic) bond coating and the ceramic TBC 
  • TBC thickness can be selected between 200 and 1,000 microns or more 
  • Standard TBC coatings are zirconium oxide with 8% yttrium oxide for phase stabilization 
  • The density of the TBC coatings, which has to be optimized for durability, is selected by setting the process parameters
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