Development of Plasma Parameters for the Manufacture of MCrAlY Bond Coats by Low‐Pressure Plasma Spraying Using a Cascaded Torch

MCrAlY bond coats (MNi, Co) for thermal barrier coating systems are often manufactured by low-pressure plasma spraying (LPPS) to achieve dense coatings with low oxygen uptake at high deposition efficiencies. Herein, the novel SinplexPro 03C spray torch (Oerlikon Metco) is characterized regarding this application, and appropriate process parameters developed. The mass-specific enthalpy hydrogen–argon gas ratio prove be substantial factors. best efficiency lowest porosity achieved a between 17 19 MJ kg−1. content increases degressively enthalpy. Already small hydrogen fractions in gas, fast route established recombination of argon ions. Consequently, treatment feedstock improved. Moreover, decreases increasing as gun operated constant current mode thus input power increases. However, slightly. On other hand, due reducing effect hydrogen. efficiency, porosity, also reasonable if no admixed all, fluctuations reduced.