Abstract: Various embodiments of the disclosure include a thermal coating powder, a system for providing a thermal spray coating, and a method for coating a component. The thermal coating powder may include fused and crushed yttria-stabilized zirconia, wherein the thermal coating powder is in a form of substantially spherically-shaped, solid particles. The system may comprise: a plasma spray gun apparatus having an exit annulus for releasing a plasma jet stream; and a powder injector port coupled to the plasma spray gun apparatus for supplying the thermal coating powder to the plasma jet stream. The method may include: providing a plasma spray gun apparatus including an exit annulus for releasing a plasma jet stream; and spraying the thermal coating powder on the component with the plasma jet stream from the plasma spray gun apparatus.

Abstract: A method of machining a profile pattern in a ceramic coating of a turbine shroud is provided and includes applying the ceramic coating substantially uniformly onto the turbine shroud, positioning a machining tool proximate the ceramic coating, and removing material from the ceramic coating by activating the machining tool to machine the ceramic coating and by moving the machining tool across the ceramic coating in a movement pattern that generally corresponds to the profile pattern.

Abstract: A method for applying at least one bond coating on a surface of a metal-based substrate is described. A foil of the bond coating material is first attached to the substrate surface and then fused thereto, e.g., by brazing. The foil is often initially prepared by thermally spraying the bond coating material onto a removable support sheet, and then detaching the support sheet. Optionally, the foil may also include a thermal barrier coating applied over the bond coating. The substrate can be a turbine engine component.

Abstract: A method for applying at least one bond coating on a surface of a metal-based substrate is described. A foil of the bond coating material is first attached to the substrate surface and then fused thereto, e.g., by brazing. The foil is often initially prepared by thermally spraying the bond coating material onto a removable support sheet, and then detaching the support sheet. Optionally, the foil may also include a thermal barrier coating applied over the bond coating. The substrate can be a turbine engine component.