Plasma spraying is a thermal spray process in which feedstock powders — including MCrAlY bond coats, yttria-stabilised zirconia (YSZ), tungsten carbide, and alumina — are injected into a high-temperature plasma arc and propelled onto substrate components to form dense, adherent coatings, with variants including atmospheric plasma spray (APS), vacuum plasma spray (VPS), and low-pressure plasma spray (LPPS) used to apply thermal barrier coatings (TBCs), wear-resistant, and corrosion-resistant layers to turbine blades, vanes, and structural airframe parts.
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