Abstract: A method of applying thermal barrier coating systems to a metal piece having a cooling hole extending along a central axis through the piece from a first surface of the piece to a second surface opposite the first surface. The method includes spraying a bond coat and a thermal barrier coating on the first surface at an angle and to a thickness to prevent the bond coat and thermal barrier coating from entirely filling the hole. The method also includes spraying a high pressure fluid jet from an elongate nozzle assembly having an orifice configured to direct the jet laterally away from the nozzle assembly toward the hole and in a direction generally parallel to the central axis of the hole.

Abstract: A method of applying thermal barrier coating systems to a metal piece having a cooling hole extending along a central axis through the piece from a first surface of the piece to a second surface of the piece opposite the first surface. The method includes spraying a bond coat on the first surface of the piece and spraying a thermal barrier coating on the bond coat. Further, the method includes spraying a high pressure fluid jet from a nozzle toward the hole and in a direction generally parallel to the central axis of the hole. The fluid jet is substantially free of solid particulate thereby permitting the jet to remove the bond coat and the thermal barrier coating from the hole without removing metal from the piece.