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. 

MITC2015-pp 286-287