Material systems for repair of thermal barrier coating and methods thereof

A method for repairing a thermal barrier coating deposited on a component with localized spallation of the thermal barrier coating, comprising:

• depositing a primer slurry on a thermally grown oxide of the component exposed by the localized spallation, the primer slurry comprising a primer that includes at least one of a metal and a metal oxide;
• depositing a ceramic slurry on the primer slurry, the ceramic slurry comprising a ceramic material, a ceramic slurry binder material, and a ceramic slurry fluid carrier;
• and
• heating the primer slurry and the ceramic slurry to form a first chemical bond between the primer and the thermally grown oxide and a second chemical bond between the primer and the ceramic material, wherein heating the primer slurry and the ceramic slurry forms a primer layer comprising the primer directly bonded to the thermally grown oxide via the first chemical bond and a repair thermal barrier coating comprising the ceramic material directly bonded to the primer layer via the second chemical bond, wherein the primer layer has a thickness between 0.2 mils and 0.6 mils.