Looking suggestion for S2B "Z" notch coating & dove tail ARC spray aluminium coating

[demionkrishan]

Dear thermal spray family, 
Is anyone here, doing Gas turbine stage 2 bucket plasma "Z" notch and dovetail Arc spray aluminium coating?
 I am totally new to this subject and I feel personally, it is time consuming process to mask the whole area with plasma tape to coat a very small area. The time for masking per piece is on an average 15 minutes, is there any way to reduce time or any other methods? Appreciate your valuable feedback 🙏

[Artyom]

Hello demionkrishan!

One of the industry leaders in manufacturing of Heavy-Duty gas turbines uses the following:
Regarding Z notch
1) Hard face coating by HVOF, no post-coating machining is required, but, extensive masking is needed.
2) Pre-machining to prepare a pocket, then hard face overlaying by Laser cladding or TIG welding with CNC grinding (not milling) to meet final contour.

Regarding Dovetail aluminum sealing coating:
1) Arc spray - chip and simple, but extensive masking and post-coating blending are required
2) Cold spray using a specially designed small nozzle which provides the width of the spray spot equal to the width of the sealing strip to be sprayed. You can ask somebody from Alabama Laser for help. https://www.alspi.com/laser.htm

Kind regards,
Artyom