Thermal barrier coating

An article comprising a thermal barrier coating comprising zirconia and a second oxide for stabilizing zirconia on a surface of a substrate, said coating having at least a layer portion comprising primary columnar grains that extend transversely of said surface and that have secondary columnar grains extending laterally therefrom relative to a respective column axis along the lengths of said primary columnar grains.

An article comprising a substrate, a metallic bondcoat on the substrate, and a thermal barrier coating on said bondcoat, said coating comprising multiple layers wherein one of said layers comprises primary columnar grains that extend transversely of said bondcoat and that have secondary columnar grains extending laterally therefrom relative to a respective column axis.

A method of forming a ceramic coating on a surface of a substrate, comprising:

• evaporating ceramic material from at least one source thereof in a coating chamber and controlling deposition of ceramic material on said surface to form primary columnar grains that extend transversely from a surface of said substrate and that have secondary columnar grains that extend laterally therefrom relative to a respective column axis.

A method of forming a ceramic thermal barrier coating on a surface of a component, comprising:

• forming a bondcoat on said component, and
• evaporating ceramic material from at least one source thereof by impinging said source with an electron beam in a coating chamber and controlling deposition of said ceramic material on said surface to form primary columnar grains that extend transversely from a surface of said bondcoat and that have secondary columnar grains that extend laterally therefrom relative to a respective column axis along lengths of said primary columnar grains.