Patent ID: 8617637

Claim:
A plasma spray coating method for forming a thermal barrier coating by performing a plasma spraying on a metal surface of a heat resistant apparatus, the method comprising: establishing plasma spraying conditions, wherein said establishing sequentially includes: (a) applying a resin to be cured with light in a liquid state on the whole metal surface to be plasma-sprayed, (b) placing test specimens made of the same material as the material of which the heat resistant apparatus is made on the resin to be cured with light, and then radiating the resin with light so as to cure the resin, such that the curing forms a heat resistant resin coating film covering the metal surface and the curing bonds the test specimens to the heat resistant resin coating film, (c) plasma-spraying a thermal barrier coating material on surfaces of the test specimens bonded to the heat resistant resin coating film, (d) removing the test specimens from the heat resistant resin coating film, and confirming the plasma spraying conditions so as to establish production plasma spraying conditions, (e) removing the heat resistant resin coating film from the metal surface, and then forming the thermal barrier coating by plasma-spraying the thermal barrier coating material on the metal surface under the established production plasma spraying conditions.