Deposition Process Research Articles

ELECTRO RECOVERY OF TELLURUM IONS FROM NON-AQUEOUS N-N DIMETHYLFORMAMIDE ELECTROLYTE

The work presents studies of the mechanism of recovery of tellurium ions from non-aqueous N-N dimethylformamide. For this, linear and cyclic current-voltage polarization curves have been recorded. The influence on the process of the concentration of tellurium ions, change of potential sweep rate and temperature has been investigated. By recording linear polarization curves, it has been established that the reducing process of tellurium ions is controlled by their diffusion to the cathode surface. The influence of the concentration of its ions in the electrolyte, the rate of change of the potential and the temperature on the tellurium deposition process was studied. By recording the cyclic polarization curve, the potential area where tellurium ions precipitate and its anodic dissolution occurs is determined. It was determined that the increase in the concentration of tellurium ions and the temperature increases the speed of the reduction process of tellurium, and the reduction process itself is controlled by the diffusion of tellurium ions on the cathode surface. To confirm the obtained data, polarization curves have been recorded on a rotating platinum disk electrode. Data received, exactly the linear dependence of ip on the electrode rotation speed (ω) to the power of 0.5, confirms that, that the process of reduction of tellurium electrodes in non-aqueous N-N dimethylformamide is controlled by diffusion polarization

Thick piezoelectric films by aerosol deposition at room temperature: corona poling and force sensing

In this study, we employed corona poling to improve the piezoelectric properties of as-deposited BaTiO3 films and conducted a vibration energy harvesting test. Dielectric measurements indicated that the dielectric constant of the as-deposited film increased with temperature, and the frequency dependence of the dielectric constant was minimal at room temperature. Applying an electric field of 1500 kV cm−1 resulted in a recoverable energy density of 7.1 J cm−3 and an energy storage efficiency of 54%. The corona polarization treatment could align dipoles under high electric fields and prevent dielectric breakdown owing to local defects created by the aerosol deposition (AD) process. The vibration test yielded a harvested energy of 172 nJ and an output voltage of 2.67 V, which is suitable for force sensor applications. Polarization via corona discharge is also feasible without an electrode. Integrating AD with corona poling may benefit new capacitors, sensors, and energy harvesting technologies.

A New Paradigm for Semiconductor Manufacturing: Integrated Synthesis, Delivery, and Consumption of Source Chemicals for IC Fabrication

The semiconductor industry is being radically impacted by the placing of greater emphasis on the development of hetero-devices and systems that will act as essential drivers for a wide spectrum of technological applications. The introduction of new materials and their integration with currently used materials are projected to replace integrated circuitry (IC) design and device scaling as the key enablers to the realization of improved device performance and larger density gains. Yet material selection has been constrained by existing fabrication process technology. To date, fabrication processes have dictated material selection by limiting chemical sources or precursors to those that match existing process tools associated with chemically based vapor phase processes and their variants, which in turn limits material compositions in ICs. The processing and integration of new materials compositions and structures will require the introduction of new deposition and etching processes, and manufacturing worthy tool designs and associated protocols that provide new methods for atomic-level control. To this end, a novel manufacturing paradigm is presented comprising a method and system for real-time, closed-loop monitoring and control of synthesis, supply, and consumption of precursors in process intensification techniques including chemical vapor deposition (CVD), atomic layer deposition (ALD), atomic layer etching (ALE), and other IC manufacturing processes. This intelligent automated manufacturing approach is consistent with a central component of the semiconductor industry’s recent adoption of Industry 4.0., including vertical integration of IC manufacturing through robotization, artificial intelligence, and cloud computing. Furthermore, the approach eliminates several redundant steps in the synthesis, handling, and disposal of source precursors and their byproducts for CVD, ALD, ALE and other chemically based manufacturing processes, and thus ultimately lowers the manufacturing cost for both conventional and new IC materials. Further, by eliminating the issues associated with precursor thermal, chemical, and pyrophoric instabilities, this new paradigm enables the deposition of a myriad of new thin-film materials and compositions for IC applications that are practically unattainable with existing precursors. Preliminary and planned demonstration examples for the generation and deposition of highly toxic and unstable source precursors are provided.

Laves phase control and tensile properties optimization of DED-arc repaired 718Plus components through the addition of TiC and Cr2C3

Directed energy deposition-arc (DED-arc) additive manufacturing technology was used to repair the damaged 718Plus components. This work shows that TiC/Cr2C3 addition to 718Plus alloy is an effective way to suppress the formation of the unfavorable Laves phase. TiC additions to 718Plus alloy can alleviate the elemental segregation, refine the dendritic structure and promote the formation of blocky TiC-NbC core-shell carbides and NbC carbides, while Cr2C3 additions enable the precipitation of rod-like NbC carbides. During the deposition process, the TiC/Cr2C3 additions were dissolved into the molten pool and decomposed into Ti, Cr, and C. The introduction of additional carbon in the melt drastically consumed the Nb available for Laves phase. The tensile tests show that TiC addition to 718Plus alloy contributed to an increased tensile strength of about 120 MPa due to the reduced amount of Laves phase and the reinforced effect of carbides. The fracture behaviour of carbides was explained in detail. The critical shear stress for blocky carbides to crack is higher than that required for rod-like ones, suggesting that TiC additions were desirable for better ductility compared with Cr2C3 additions.

How dependent are quantitative volcanic ash concentration and along‐flight dosage forecasts to model structural choices?

AbstractProducing quantitative volcanic ash forecasts is challenging due to multiple sources of uncertainty. Careful consideration of this uncertainty is required to produce timely and robust hazard warnings. Structural uncertainty occurs when a model fails to produce accurate forecasts, despite good knowledge of the eruption source parameters, meteorological conditions and suitable parameterizations of transport and deposition processes. This uncertainty is frequently overlooked in forecasting practices. Using a Lagrangian particle dispersion model, simulations with varied output spatial resolution, temporal averaging period and particle release rate are performed to quantify the impact of these structural choices. This experiment reveals that, for the 2019 Raikoke eruption, structural choices give measurements of peak ash concentration spanning an order of magnitude, significantly impacting decision‐relevant thresholds used in aviation flight planning. Conversely, along‐flight dosage estimates exhibit less sensitivity to structural choices, suggesting it is a more robust metric to use in flight planning. Uncertainty can be reduced by eliminating structural choices that do not result in a favourable level of agreement with a high‐resolution reference simulation. Reliable forecasts require output spatial resolution 80 km, temporal averaging periods 3 h and particle release rates 5000 particles/h. This suggests that simulations with relatively small numbers of particles could be used to produce a large ensemble of simulations without significant loss of accuracy. Comparison with previous Raikoke simulations indicates that the uncertainty associated with these constrained structural choices is smaller than those associated with satellite constrained eruption source parameter and internal model parameter uncertainties. Thus, given suitable structural choices, other epistemic sources of uncertainty are likely to dominate. This insight is useful for the design of ensemble methodologies which are required to enable a shift from deterministic to probabilistic forecasting. The results are applicable to other long‐range dispersion problems and to Eulerian dispersion models.

The islet tissue plasminogen activator/plasmin system is upregulated with human islet amyloid polypeptide aggregation and protects beta cells from aggregation-induced toxicity

Aims/hypothesisApart from its fibrinolytic activity, the tissue plasminogen activator (tPA)/plasmin system has been reported to cleave the peptide amyloid beta, attenuating brain amyloid deposition in Alzheimer’s disease. As aggregation of human islet amyloid polypeptide (hIAPP) is toxic to beta cells, we sought to determine whether activation of the fibrinolytic system can also reduce islet amyloid deposition and its cytotoxic effects, which are both observed in type 2 diabetes.MethodsThe expression of Plat (encoding tPA) and plasmin activity were measured in isolated islets from amyloid-prone hIAPP transgenic mice or non-transgenic control islets expressing non-amyloidogenic mouse islet amyloid polypeptide cultured in the absence or presence of the amyloid inhibitor Congo Red. Plat expression was also determined in hIAPP-treated primary islet endothelial cells, bone marrow-derived macrophages (BMDM) and INS-1 cells, in order to determine the islet cell type(s) producing tPA in response to hIAPP aggregation. Cell-free thioflavin-T assays and MS were used to respectively monitor hIAPP aggregation kinetics and investigate plasmin cleavage of hIAPP. Cell viability was assessed in INS-1 beta cells treated with hIAPP with or without plasmin. Finally, to confirm the findings in human samples, PLAT expression was measured in freshly isolated islets from donors with and without type 2 diabetes.ResultsIn isolated islets from transgenic mice, islet Plat expression and plasmin activity increased significantly with the process of amyloid deposition (p≤0.01, n=5); these effects were not observed in islets from non-transgenic mice and were blocked by Congo Red (p≤0.01, n=4). In response to hIAPP exposure, Plat expression increased in BMDM and INS-1 cells vs vehicle-treated cells (p≤0.05, n=4), but not in islet endothelial cells. Plasmin reduced hIAPP fibril formation in a dose-dependent manner in a cell-free system, and restored hIAPP-induced loss of cell viability in INS-1 beta cells (p≤0.01, n=5). Plasmin cleaved monomeric hIAPP, inducing a rapid decrease in the abundance of full-length hIAPP and the appearance of hIAPP 1–11 and 12–37 fragments. hIAPP 12–37, which contains the critical amyloidogenic region, was not toxic to INS-1 cells. Finally, PLAT expression was significantly increased by 2.4-fold in islets from donors with type 2 diabetes (n=4) vs islets from donors without type 2 diabetes (n=7) (p≤0.05).Conclusions/interpretationThe fibrinolytic system is upregulated in islets with hIAPP aggregation. Plasmin rapidly degrades hIAPP, limiting its aggregation into amyloid and thus protecting beta cells from hIAPP-induced toxicity. Thus, increasing islet plasmin activity might be a strategy to limit beta cell loss in type 2 diabetes.Graphical

Galling-Free Forging of Titanium Using Carbon-Supersaturated SiC Coating Dies

The thermal chemical vapor deposition (CVD) process was utilized to fabricate 6H-structured SiC coating dies with carbon control. The carbon-rich clusters along the SiC grain boundaries acted as a pinning site to suppress irregular crystal growth and to homogenize the fine-grained structure. These massive carbon-supersaturated (MCSed) SiC dies with a thickness of 4 mm were utilized for upsetting pure titanium bars in dry and cold conditions. Under a stress gradient from the contact interface to the depth of the SiC coating, the carbon solute isolated from these carbon clusters diffused through the grain boundaries and formed free carbon agglomerates on the contact interface to the pure titanium bars. These in situ-formed free carbon agglomerates acted as a solid lubricant to sustain the friction coefficient at 0.09 at the hot spots on the contact interface and to protect the dies and bars from severe adhesive wearing.

Bilateral Production Shield Enabling Highly Efficient Perovskite Photovoltaics.

Enhancing the intrinsic stability of perovskite and through encapsulation to isolate water, oxygen, and UV-induced decomposition are currently common and most effective strategies in perovskite solar cells. Here, the atomic layer deposition process is employed to deposit a nanoscale (≈100nm), uniform, and dense Al2O3 film on the front side of perovskite devices, effectively isolating them from the erosion caused by water and oxygen in the humid air. Simultaneously, nanoscale (≈100nm) TiO2 films are also deposited on the glass surface to efficiently filter out the ultraviolet (UV) light in the light source, which induces degradation in perovskite. Ultimately, throughthe collaborative effects of both aspects, the stability of the devices is significantly improved under conditions of humid air and illumination. As a result, after storing the devices in ambient air for 1000h, the efficiency only declines to 95%, and even after 662h of UV exposure, the efficiency remains at 88%, far surpassing the performance of comparison devices. These results strongly indicate that the adopted Al2O3 and TiO2 thin films play a significant role in enhancing the stability of perovskite solar cells, demonstrating substantial potential for widespread industrial applications.

Laser-Directed Energy Deposition of Ti-Mo Biomaterials: Influencing Mechanisms of Molybdenum on Microstructure and Performance

Ti-Mo alloys with variable molybdenum (Mo) contents were fabricated by the laser-directed energy deposition process. The in-depth influencing mechanisms of the Mo element on microstructure and performance were quantitatively analyzed by experiment and first-principal calculation. Increasing Mo content decreased the formation and cohesive energies and stabilized the 𝛽 phase. The grain refining efficiency was increased, and the relative grain size was decreased by increasing the Mo content. The MS temperature decreased, and the acicular martensite formed with increasing Mo content. Both the solid-solution hardening and fine grain strengthening effects had positive influences, while the 𝛽 phase softening effect had a negative influence on the hardness and wear performance with increasing Mo content.

Low‐Temperature Synthesis of Stable CaZn2P2 Zintl Phosphide Thin Films as Candidate Top Absorbers

AbstractThe development of tandem photovoltaics and photoelectrochemical solar cells requires new absorber materials with bandgaps in the range of ≈1.5–2.3 eV, for use in the top cell paired with a narrower‐gap bottom cell. An outstanding challenge is finding materials with suitable optoelectronic and defect properties, good operational stability, and synthesis conditions that preserve underlying device layers. This study demonstrates the Zintl phosphide compound CaZn2P2 as a compelling candidate semiconductor for these applications. Phase‐pure, ≈500 nm‐thick CaZn2P2 thin films are prepared using a scalable reactive sputter deposition process at growth temperatures as low as 100 °C, which is desirable for device integration. Ultraviolet‐visible spectroscopy shows that CaZn2P2 films exhibit an optical absorptivity of ≈104 cm−1 at ≈1.95 eV direct bandgap. Room‐temperature photoluminescence (PL) measurements show near‐band‐edge optical emission, and time‐resolved microwave conductivity (TRMC) measurements indicate a photoexcited carrier lifetime of ≈30 ns. CaZn2P2 is highly stable in both ambient conditions and moisture, as evidenced by PL and TRMC measurements. Experimental data are supported by first‐principles calculations, which indicate the absence of low‐formation‐energy, deep intrinsic defects. Overall, this study shall motivate future work integrating this potential top cell absorber material into tandem solar cells.

Comparative studies on pinhole free CBD-CdZnS thin films on ITO and FTO substrate

The development of CdZnS thin films using the chemical bath deposition process in nonaqueous media is a technological challenge. In this work, 75 millilitres of ethylene glycol and ethanol (1:2 ratios) were used to develop a CdZnS thin film on ITO and FTO glass substrates using cadmium acetate, zinc sulphate, and thiourea. The ideal bath temperature was kept at 1300C and the anneal temperature of the film that had been deposited in the air was maintained at 3500C. The films have been examined using FTIR, WCA, FESEM, and XRD. XRD studies reveal that CdZnS films have a hexagonal crystal structure with a preference for orientation (002) during the deposition and annealing processes and the assessment of the various attributes have been done, such as dislocation density, micro strain, and grain size. FESEM study indicates that as deposited film on ITO glass have smooth surface and grains appear in the form of small needle shape of equal sizes where as FTO substrate reveals the grains of equal size throughout the entire surface in cluster form. It is also confirmed that both the CdZnS films formed on ITO and FTO substrates have hydrophilic quality. The presence of chemical bonds and functional groups was confirmed by FTIR analysis.

Quantifying the Contribution of Multiple Processes to the Dust Decreasing Trend in the Guliya Ice Core Over the Past 50 Years

AbstractDust records extracted from ice cores can facilitate the reconstruction of historical atmospheric dust levels and climate change. However, interpreting dust variations in ice cores is intricate because of the compounded influence of emission, transport, and deposition processes. This study investigated dust records retrieved from the Guliya ice cap drilled in 2015 on the West Tibetan Plateau using a mean trajectory transport and deposition model. Results showed that the Guliya dust concentration has exhibited a declining trend since the 1960s (−751 μg kg−1 yr−1). Applying an attribution approach, we discovered that low dust emission (80.3%) was the main cause of the drop in dust concentration, with changes related to transportation (5.2%) and deposition (14.5%) making only minor contributions. The weakening of surface wind speed in the desert and increasing precipitation in both the desert and glacier were the primary factors driving the decrease in Guliya dust concentration.

Surface engineering of TiSiO4 nano-coating for high-voltage nickel-rich ternary cathodes: An approach to improve cyclic performance

In recent years, layered ternary transition metal oxides with a high nickel content have gained substantial attention as a potential positive electrode material for lithium-ion batteries. However, its poor rate capability, cyclability, and capacity retention at high working voltages limit its use in commercial lithium-ion batteries. To overcome these challenges, we synthesize a cost-effective wet-chemical deposition of novel TiSiO4 nano-coatings over the surface of LiNi0.83Mn0.06Co0.11O2 (NMC-83). X-ray diffraction and electron microscopy confirm the presence of a coating and verify that the deposition process did not alter the crystallinity and morphology of the NMC-83 particles. In addition, during cycling, it completely protects NMC-83 with enhancements in hexagonal phase transitions between H2 and H3, resulting in excellent cycling stability at upper cut-off voltages. Likewise, when the amount of coated material is equal to 1 wt%, it provides faster ion kinetics and a stable electrode-electrolyte interface. The 1 wt% TiSiO4 coating provides 35 % retention after 250 cycles at a 0.5C rate, while the pristine NMC-83 shows only 13.7 %. From postmortem analysis, the 1 wt% TiSiO4-coated NMC-83 cathode maintains its stable polycrystalline nature compared with pristine NMC-83. Thus, this novel TiSiO4 nanocoating has significant implications for developing high-performance rechargeable batteries for energy applications.

An Insight in to Cadaveric Ectopic Calcification: A Case Report

Abstract: Pathological Calcification is an anomalous accumulation of calcium salts along with minimal quantities of iron, magnesium and other minerals in bodily tissues except teeth and bone causing hardening of the affected tissues. The location of the calcification and the presence or absence of mineral balance can be used to categorize it. The atypical mineral deposition processes in biological systems can sometimes be referred to as pathological calcification. During the routine dissection in National Institute of Ayurveda, Jaipur it was observed that numerous pathological calcifications were present both on osseous and extra osseous sites which were different from the normal human anatomy. The subject was a 90-year-old male of North Indian origin. Case examples illustrate different types and locations of calcification, shedding light on the anatomical distribution and potential clinical relevance.

Influence of the Acetylene Flow Rate and Process Pressure on the Carbon Deposition Behavior by Thermal Chemical Vapor Deposition Process

We used the chemical vapor deposition process to deposit carbon film at a high temperature (900 °C). The carbon films were deposited on AISI 1006 foils using an acetylene gas. We analyzed the carbon film deposited on the surface using Raman spectroscopy, scanning electron microscopy, and high-resolution transmission electron microscopy to define changes in the bonding structure of the carbon film. The results of Raman spectroscopy and high-resolution transmission electron microscopy revealed that as the acetylene flow rate increased, the shape of the deposited carbon film changed from graphene to graphite. In addition, in order to compare the quality of the carbon film in terms of mechanical and electrical properties, carbon films treated under various conditions were closely analyzed using nano-indenter and a sheet resistance meter. Therefore, the optimal condition (1 Torr-50 sccm) was selected in which graphene was uniformly deposited and had the lowest electrical resistance (500 Ω/sq) and highest hardness (12 GPa).

Modeling the influence of the duration of water vapor pulses on the properties of hafnium oxide synthesized by atomic layer deposition method

The work experimentally and theoretically analyzes the process of atomic layer deposition of hafnium oxide with the participation of water vapor as an oxidizing agent. The study of infrared absorption, Auger spectroscopy and luminescence shows that with increasing water pulse duration, the concentration of oxygen vacancies decreases and the composition tends to stoichiometric, which is given by the formula HfO2. Modeling of gas dynamics and kinetics of film synthesis by atomic layer deposition was performed, which showed the dependence of the coverage of the film surface with oxygen on the pulse duration and deposition temperature. A comparison of calculations with experimental results made it possible to estimate the magnitude of the kinetic coefficients of the synthesis processes that describe the observed experimental dependences and to show that the larger of the two temperatures of the atomic layer deposition window is associated with water desorption.

The detection of acetone in exhaled breath using gas Pre-Concentrator by modified Metal-Organic framework nanoparticles

Volatile organic compounds (VOCs) from exhaled breath are promising indicators for the diagnostics of human health conditions. However, the composition of breath is rather complex, including water vapors and various tiny amounts of gases and biomarkers. Pre-concentrator plays a significant role in capturing and concentrating target gas in the gas mixture. In this work, the MIL-101 (Cr) nanoparticles are coated with polydimethylsiloxane (PDMS) through physical vapor deposition process to concentrate acetone under high humidity and room temperature. Experimentally, the newly developed material exhibits significant improvement in signal intensity that is 76.3 times greater than a commercial reference material under relative humility of 80 %. The detection range is also proven to be desirable (from 100 ppb to 2500 ppb), capturing the spectrum of acetone concentrations typically found in human exhaled breath. Moreover, following a thermal desorption process, the device demonstrates a high degree of linearity with a coefficient of 0.9956. The modified metal–organic framework materials are made into a flexible thin-film-shape device, that could be embedded in a facemask. The proposed device could meet the critical requirements for sampling, concentrating and detecting of exhaled breath biomarkers, thereby opening a new opportunity as part of the flexible electronic systems on face masks to facilitate quantitative breath analyses.

A novel data-driven framework for enhancing the consistency of deposition contours and mechanical properties in metal additive manufacturing

The accuracy and quality of part formation are crucial considerations. However, the laser directed energy deposition (L-DED) process often leads to irregular changes in deposition contours and mechanical properties across parts due to complex flow fields and temperature variations. Hence, to ensure the forming accuracy and quality, it is necessary to achieve precise monitoring and appropriate parameter adjustments during the processing. In this study, a machine vision method for real-time monitoring is proposed, which combines target tracking and image processing techniques to achieve accurate recognition of deposition contours under noisy conditions. Through comparative verification, the measurement accuracy reaches as high as 98.98 %. Leveraging the monitoring information, a bidirectional prediction neural network is proposed to accomplish layer-by-layer forward prediction of layer height. Meanwhile, inverse prediction is employed to determine the processing parameters required for achieving the desired layer height, facilitating the optimization of the deposition contours. It was found that as the processing parameters were adjusted layer-by-layer to achieve consistent deposition contours, there was also a tendency towards consistent changes in microstructure and mechanical properties. The standard deviations of primary dendrite arm spacing (PDAS) and ultimate tensile strength (UTS) at different positions decrease by over 52.2 % and 61.4 %, respectively. This study reveals the consistent patterns of variation in deposition contours and mechanical properties under data-driven variable parameter processing, laying an important foundation for future exploration of the complex process-structure-performance (PSP) relationship in L-DED.

Investigating the effect of SiO2 thin films with sculptured topographies on the alignment properties of liquid crystals

In the present work, sculptured thin films (STF) based on silicon dioxide (SiO2) induced on the indium tin oxide (ITO) coated substrates via glancing angle deposition (GLAD) technique using the physical vapor deposition (PVD) process. Our main motive to perform this work is to address the issues we have faced with the traditional alignment method and give a try to overcome those problems. Keeping these challenges in our mind, we are giving here an alternative to traditional method and explored this different alignment technique with GLAD process. We have fabricated a liquid crystal device (LCD) in a way of electrically-controlled birefringence (ECB) and placed the engineered substrates in anti-parallel alignment. Morphological, optical and electro-optic behaviour of resulting device has been studied in the ∼5 μm thick device. Effect of applied voltage on the morphology and electro-optic behaviour of liquid crystal has been established. Interestingly, LC material demonstrates electrically switchable birefringence colours viz. brown, green, pink, purple and mauve colour, under applied electric field in room temperature at 10X magnification under polarizing optical microscope. A very nice extinction and contrast has been obtained with fabricated ECB device, which elucidate the device quality with impeccable alignment without any disclination defects. Besides, the electro-optic characteristics it also shows a significant impact on the liquid crystal properties. The obtained results demonstrate nice optical retardation, a lower Frederick's threshold voltage i.e. 1.5 V and 19.03 dB higher contrast respectively. An impressive switching response time τon of 5.4 ms and τoff = 600 µs at 20 V has attained with respective device as well. Such change in parameters may correspond to the higher electrical torque experienced by the LC molecules on the application of applied field. Anchoring energy and pretilt angle of respective system has been calculated and correlated with observed behaviour. Thus, engineered device with this superior alignment method show remarkable electro-optic results which can open a new way for the development of fast LCD for advanced optical device applications.

Investigation of the cooling hole blockage induced by different thermal spray TBC deposition processes

High-temperature turbine airfoils and combustion chamber walls in jet engines require sufficient cooling via cooling holes and thermal barrier coating systems (TBCs) to protect them from hot combustion gases. As the demand for greater efficiency and higher firing temperatures in jet engines increases, there is a corresponding need for more advanced film cooling methods, such as the use of more complex hole geometries. The use of Additive Layer Manufacturing (ALM) techniques allows the production of such intricate cooling holes, enhancing the flow of cooling air onto component surfaces. Conventional TBC deposition techniques, for example Atmospheric Plasma Spraying (APS) or Electron Beam Physical Vapor Deposition (EB-PVD), often lead to partial or complete blockage of cooling holes. This study compares the blockage of TBCs deposited on conventionally-sheet alloys with standard cooling holes and ALM alloys with more complex cooling holes using APS as a baseline process. Additionally, alternative plasma spray deposition technologies such as Suspension Plasma Spraying (SPS) and Plasma Spray-Physical Vapor Deposition (PS-PVD) were explored. The aim was to determine the effectiveness of these processes in preventing blockage compared to the traditional APS process. The experimental results showed that the formation of the coating, whether originating from splats or from the vapor phase, the feedstock particle size, and the cooling hole geometry can all affect the blockage. It was demonstrated that PS-PVD, with its vapor-induced deposition, is highly effective in minimizing blockage, regardless of the cooling hole geometry.