Patent ID: 8367967

Claim:
A microplasma spray apparatus for repairing a thermal barrier coating on components in a gas turbine engine, comprising: a microplasma gun including an anode, a cathode, and an arc generator for generating an electric arc between the anode and cathode; a nozzle for emitting arc gas into the electric arc, the electric arc operable for ionizing the gas to create a plasma gas stream; and a powder injector for injecting powdered thermal barrier coating material into the plasma gas stream and patching a defective area of the thermal barrier coating, the thermal barrier coating being applied without masking any portion of the component or stripping a remaining non-defective thermal barrier coating on the component, wherein said cathode includes an electrode extending therefrom and disposed through an aperture of said nozzle, and said anode is disposed opposite said cathode within an anode holder mounted to an exterior surface of said microplasma gun.