Thermal barrier coating ceramic structure

A method of producing a ceramic topcoat of a thermal barrier coating system on a substrate, the method of 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 while moving the substrate from the first orientation to a second orientation to produce a curved columnar grain microstructure with a first curved grain orientation direction;
• and
• c) depositing a second ceramic layer on the substrate while moving the substrate from the second orientation to the first second orientation to produce a curved columnar grain microstructure with a different curved grain orientation direction.

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 curved columnar grain microstructure with a curved grain orientation direction and a second ceramic layer disposed on the first ceramic layer, the second ceramic layer having a curved columnar grain microstructure with a different curved 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 curved columnar grain microstructure with a curved grain orientation direction and a second ceramic layer disposed on the first ceramic layer, the second ceramic layer having a curved columnar grain microstructure with a different curved grain orientation direction.

A thermal barrier coating system comprising:

• a bond coat for applying to a substrate;
• an alumina layer on the bond coat;
• and
• a ceramic topcoat on the alumina layer comprising a plurality of superposed ceramic layers, each layer having a grain orientation direction which differs from its abutting layers and forming a columnar grain microstructure with intercolumnar gaps which extend at least substantially down to the alumina layer.

A coated article comprising:

• a substrate;
• and
• a thermal barrier coating applied to the substrate comprising a bond coat for on the substrate;
• an alumina layer on the bond coat;
• and
• a ceramic topcoat on the alumina layer comprising a plurality of superposed ceramic layers each layer having a grain orientation direction which differs from its abutting layers and forming a columnar grain microstructure with intercolumnar gaps which extend at least substantially down to the alumina layer.

A method for producing a thermal barrier coating system comprising the steps of:

• applying a bond coat to a substrate;
• applying an alumina layer on the bond coat;
• and
• applying a ceramic topcoat on the alumina layer by applying a plurality of superposed ceramic layers thereon, each layer having a grain orientation direction which differs from its abutting layers and forming a columnar grain microstructure with intercolumnar gaps which extend at least substantially down to the alumina layer.