Thermal barrier coating ceramic structure

A thermal barrier coating system comprising:

• a bond coat;
• an alumina layer on the bond coat;
• and
• a ceramic topcoat on the alumina layer, the ceramic topcoat comprising:
• a first ceramic layer having a generally columnar grain microstructure with a first grain orientation direction;
• and
• a second ceramic layer disposed thereon having a generally columnar grain microstructure with a different grain orientation direction.

A coated article comprising:

• a substrate;
• and
• a thermal barrier coating system on the substrate, the thermal barrier coating system comprising:
• a bond coat on the substrate;
• an alumina layer on the bond coat;
• and
• a ceramic topcoat on the alumina layer, the ceramic topcoat comprising:
• a first ceramic layer having a generally columnar grain micro structure with a first grain orientation direction;
• and
• a second ceramic layer disposed thereon having a generally columnar grain microstructure with a different grain orientation direction.

A method of producing a ceramic topcoat of a thermal barrier coating system on a substrate, the method comprising the steps of:

• a) providing a substrate at a first orientation relative to a source of ceramic vapor;
• b) depositing a first ceramic layer on the substrate at the first orientation to produce a generally columnar grain microstructure with a first grain orientation direction;
• c) moving the substrate to a second orientation relative to the ceramic vapor source;
• and
• d) depositing a second ceramic layer on the substrate at the second orientation to produce a generally columnar grain microstructure with a different grain orientation direction.