An electron beam physical vapor deposition (EBPVD) apparatus for producing a
coating
material (e.g., a ceramic thermal barrier coating) on an article. The EBPVD apparatus
generally includes a coating chamber that is operable at elevated temperatures
and subatmospheric pressures. An electron beam gun projects an electron beam into
the coating chamber through an aperture in a wall of the chamber and onto a coating
material within a coating region defined within the chamber, causing the coating
material to melt and evaporate. An article is supported within the coating chamber
so that vapors of the coating material deposit on the article. The operation of
the EBPVD apparatus is enhanced by the inclusion within the coating chamber of
a second chamber that encloses the aperture so as to separate the aperture from
the coating region. The second chamber is maintained at a pressure lower than the
coating region.