An improved CoNiCrAlY bond coat in
thermal barrier coating (TBC) was developed by
fabricating the bond coat under optimized condition
using cold spray (CS). The smoothed particle
hydrodynamics (SPH) method was used to model
CoNiCrAlY deposition and estimate the optimum
velocity which is normally obtained via costly and time
consuming experiments. The performance of TBC with
bond coat cold sprayed under optimized condition was
assessed. It was found that the TBC exhibit slow
growing undulated TGO with minimal mixed oxide.
The improved CS bond coat can reduce the probability
of spallation of the top coat and the failure of TBC.