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The use of thermal barrier coatings on high-pressure turbine components can improve gas turbine efficiency through reduction of cooling airflow. However, to reduce cooling airflow, a highly reliable thermal barrier coating is required. This increased reliability will be achievable through several complimentary approaches: material and process development, life prediction method development, and engine service experience. The results of bond coat material development, which has increased the thermal cycle life of plasma spray thermal barrier coatings, are presented. Improvements were achieved by two methods: (1) use of creep-resistant bond coat compositions, and (2) overaluminiding of the bond coat.

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