Thermal barrier coatings for aircraft engine and power generation hot section components are generally applied by thermal spray processes and most recently by EBPVD (TBC) and diffusion aluminizing (bondcoat).

This paper highlights the key features of the thermal spray, diffusion aluminizing and EBPVD coating process.

The coating characteristics of thermally sprayed MCrAlY bondcoat as well as Low Density and DVC (Zircoat™) TBC are described.

Essential features of a typical EBPVD TBC coating system, consisting of a diffusion aluminide and a columnar TBC are presented.

The major coating cost elements such as material / material efficiency, equipment and processing of are explained for the different processes.

A performance and cost comparison is given for selected examples.