To reduce the formation of detrimental complex oxides, bond coatings in the thermal barrier coatings for gas turbines are typically fabricated using vacuum plasma spraying (VPS) or the high-velocity oxygen fuel (HVOF) process. Herein, VPS and HVOF processes were applied using NiCoCrAlY + HfSi-based powder to assess the oxidation behavior of the bond coatings for both coating processes. Each coated sample was subjected to 50 cyclic heat treatments at 950 °C for 23 h and cooling for 1 h at 20 °C with nitrogen gas, and the weight change during the heat treatment was measured to evaluate the oxidation behavior. After the oxidation test, the coating layer was analyzed with X-ray diffraction (XRD), scanning electron microscopy (SEM), and energy-dispersive spectroscopy (EDS). The VPS coating exhibited faster weight gain than the HVOF coating because the alumina particles generated during the initial formation of the HVOF coating inhibited oxidation and diffusion. The VPS coating formed a dense and thick thermal growth oxide (TGO) layer until the middle of the oxidation test and remained stable until the end of the evaluation. However, the HVOF coating demonstrated rapid weight loss during the final 20 cycles. Alumina within the bond coat suppressed the diffusion of internal elements and prevented the Al from being supplied to the surface. The isolation of the Al accelerated the growth of spinel TGO due to the oxidation of Ni, Co, and Cr near the surface. The as-coated VPS coating showed higher hardness and lower interfacial bonding strength than the HVOF did. Diffusion induced by heat treatment after the furnace cyclic test (FCT) led to a similar internal hardness and bonding strengths in both coating layers. To improve the quality of the HVOF process, the densification of the coating layer, suppression of internal oxide formation, and formation of a dense and uniform alumina layer on the surface must be additionally implemented.

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