Thermal barrier coatings (TBCs) are much important parts to maintain turbine blades, vanes, and combustion parts in gas turbines. Usually, plasma spray and electron beam physical vapor deposition (EB-PVD) are used to prepare TBCs for components of gas turbines. Recently, the specialized air plasma spray (APS) equipment (TriplexPro?-200) with three plasmas and multi-hopper system is launched to improve the coating quality and enhance coating workability. The deposition efficiency is much higher than commercial APS system, and a homogeneous microstructure can be prepared . In present study, we prepared TBCs using the commercialized powders and the specialized APS coating system of TriplexPro?-200. For preparing the TBCs, powder feeding rate, gun distance, and feedstock species were controlled, and then microstructures of both bond and top coats were designed. The relationship between microstructure evolution and thermal fatigue behavior was investigated, and the advantages of designed micro- structure for thermal durability of the TBCs are discussed.
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