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The SG-100 ID Extension plasma spray guns deposit thermal spray coatings-metallics, ceramics, and carbides-onto critical industrial parts, including ID's as small as 1.5 inches. The model 2700 or model 2086A guns are mounted on a standard SG-100 gun body to simply and effectively create an ID system. The extension hardware can be used for applying nickel-based alloys and thermal barrier coatings (TBC) to coat combustion liners and transition ducts used in aircraft engines. Current activities are focused on the development of wear- and corrosion-resistant carbide coatings for use as alternatives to hard chrome plating. Other applications include wear protection of hard-to-reach surfaces such as hydraulic tools and pump liners.