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A D V A N C E D M A T E R I A L S & P R O C E S S E S | N O V E M B E R / D E C E M B E R 2 0 2 0 4 8 iTSSe TSS iTSSe TSS show the potential for an improvement by a factor of two, with longer spray distance capability, when using cascaded arc technology. ADVANCEMENTS IN MATERIALS AND PROCESSES Although many TBC applications still use traditional 7-8wt%YSZceramicswithMCrAlYbondcoats, recent demands in the marketplace require the commercialization of new ce- ramic systems. Over the past several decades, the continued development and advancement of high-temperature coating materials for turbine engines resulted in many new advanced TBC systems that were designed through new chemistries and coating architectures (Fig. 5). Today, these coating systems are being manufactured with commercially available ceramic powders that are produced using HOSP, agglomerated and sintered, or fused and crushed manufacturing processes. New chemistries are currently being designed either through tradi- tional experimentation or computational modeling, such as rapid alloy development (RAD) [8] . As engine operating temperatures continue to increase, surface solutions will need to be engineered with the use of advanced materials and creative coating architectures in order to deal with the conditions that future turbine compo- nents will encounter. Figure 5 shows a view on how the future need requires a foundation of advanced scientific engineering approaches. The coating microstructure shown in the figure illustrates how future coatings are being designed to address several challenges that face future TBCs. The microstructure represents an example of a multi-layered coating that consists of an MCrALY bond coat, 7-8 wt%YSZ intermediate layer, and a gadolinium zirconate (GZO) top coat. Together with reliable processing equipment and robust materials, these new coating systems will help to move tur- bine technology forward in the years ahead. The key to future success in the thermal spray industry will be the utilization of advanced high-enthalpy plasma spray equipment for its robustness and ability to increase coverage rates while main- taining reliability and repeatable coating microstructures. To achieve this, equipment consumables will be required to last for long periods of time and produce uniform plasma plume conditions throughout their service lives. ~iTSSe For more information: Mitchell Dorfman, FASM, product portfolio manager - High Temperature Materials, Oerlikon Metco (US) Inc., 1101 Prospect Ave., Westbury, N.Y. 11590, 516.603.8764, mitch.dorfman@oerlikon.com , www.oerlikon. com/metco. Acknowledgment The authors would like to acknowledge Dieter Sporer, Manfred Stapgens, Karen Sender, and Danie De Wet for their assistance and support of this work. References 1. Dynamic Workbook for Custom Charts – Aviation Turbo- fan Engines & Industrial Gas Turbines, Forecast International Inc., 2019. 2. D. Sporer, J. Girgulis, C. Dambra, and M. Dorfman, Seg- mented 8% YSZ Thermal Barrier Coating Solutions using Cascading Arc Gun Technology, Oerlikon Metco published document TP-0002.3, 2016.1. 3. A. Feuerstein, J. Knapp, T. Taylor, A. Ashary, A. Bol- cavage, and N. Hitchman, Technical and Economical Aspects of Current Thermal Barrier Coating Systems for Gas Turbine Engines by Thermal Spray and EBPVD: A Review, Journal of Thermal Spray Technology, Vol 17(2), June 2008, p 199-213. 4. M. Aghasiberg, F. Tarasi, R. Lima, A. Doltabadi, and C. Moreau, A Review on Suspension Thermal Spray Patented Technology Evolution, Journal of Thermal Spray Technology , online publication, August 22, 2019, Springer, https://link. springer.com/article/10.1007/s11666-019-00904-x. 5. C. Hardwicke and Y.C. Lau, Advances in Thermal Spray Coatings for Gas Turbines and Energy Generation: A Review, Journal of Thermal Spray Technology , Vol 22, June 2013, p 564. 6. D. Chen, O. Sabouni, and C. Dambra, Influence of Pro- cess Parameters and Feedstock Selection on Coating Mi- crostructures and Properties with a Cascaded SinplexPro Plasma Torch, ITSC , 2014, p 48-52. 7. D. Chen, R. Rocchio-Heller, and C. Dambra, Segment- ed Thermal Barrier Coatings for ID and OD Components Using the SinplexPro Plasma Torch, Journal of Thermal Spray Technology, 28, p 1664-1673, 2019. 8. J. Cheney, Utilizing Big Data Informatics for Thermal Spray Materials Design, International Thermal Spray Confer- ence and Exposition, Orlando, Fla., May 2018. FEATURE 12