Abstract: A tri-barrier ceramic coating system is provided having a base thermal barrier layer, an intermediate CMAS barrier layer, and a top erosion barrier layer, and the method of applying such a coating system to a substrate. The base layer has a typical columnar structure with inter-columnar gaps and intra-columnar micro-pores that provides the stress tolerance during thermal cycles. The intermediate CMAS barrier layer has the fiber-like columns with inter-columnar nano-pores and a grid structure on the bottom of the layer. The fine structured intermediate layer covers the gaps between the columns of the base layer and will block CMAS infiltration effectively. The top erosion resistant layer contains wider TBC columns with narrow inter-columnar gaps and a modified cauliflower-like TBC head that provides erosion resistance for the underlying layers. The tri-barrier coating microstructure will further reduce the thermal conductivity as comparing to the conventional single layer system.

Abstract: A tri-barrier ceramic coating system is provided having a base thermal barrier layer, an intermediate CMAS barrier layer, and a top erosion barrier layer, and the method of applying such a coating system to a substrate. The base layer has a typical columnar structure with inter-columnar gaps and intra-columnar micro-pores that provides the stress tolerance during thermal cycles. The intermediate CMAS barrier layer has the fiber-like columns with inter-columnar nano-pores and a grid structure on the bottom of the layer. The fine structured intermediate layer covers the gaps between the columns of the base layer and will block CMAS infiltration effectively. The top erosion resistant layer contains wider TBC columns with narrow inter-columnar gaps and a modified cauliflower-like TBC head that provides erosion resistance for the underlying layers. The tri-barrier coating microstructure will further reduce the thermal conductivity as comparing to the conventional single layer system.

Abstract: This invention provides a thermal barrier ceramic coating for application to a metallic article, with the ceramic coating having a formula of NdxZr1-xOy with Z dissolved in, where 0<x<0.5 and 1.75<y<2 and wherein Z is an oxide of a metal selected from the group consisting of Y, Mg, Ca, Hf and mixtures thereof. In one embodiment Nd is added at a level up to 7 mole %. In another embodiment Z is yttrium and is added at a level of at least 6 wt %.

Abstract: This invention provides a thermal barrier ceramic coating for application to a metallic article, with the ceramic coating having a formula of NdxZr1?xOy with Z dissolved in, where 0<x <0.5 and 1.75<y<2 and wherein Z is an oxide of a metal selected from the group consisting of Y, Mg, Ca, Hf and mixtures thereof. In one embodiment Nd is added at a level up to 7 mole %. In another embodiment Z is yttrium and is added at a level of at least 6 wt %.

Abstract: This invention provides a thermal barrier ceramic coating for application to a metallic article, with the ceramic coating having a formula of RexZr1-xOy with Z dissolved in wherein Re is a rare earth element selected from the group consisting of Ce, Pr, Nd, Pm, Sm, Eu, Tb, Dy, Ho, Er, Tm, Yb and Lu, where 0<x<0.5 and 1.75<y<2 and wherein Z is an oxide of a metal selected from the group consisting of Y, Mg, Ca, Hf and mixtures thereof. A preferred embodiment is wherein Re is Nd and Z is yttrium oxide.

Abstract: This invention provides a thermal barrier ceramic coating for application to a metallic article, with the ceramic coating having a formula of RexZr1−xOy wherein Re is a rare earth element selected from the group consisting of Ce, Pr, Nd, Pm, Sm, Eu, Tb, Dy, Ho, Er, Tm, Yb and Lu where O<X<0.5 and 1.75<Y<2. A preferred embodiment is wherein Re is Nd.

Abstract: This invention provides a thermal barrier ceramic coating for application to a metallic article, with the ceramic coating having a formula of RexZr1-xOy wherein Re is a rare earth element selected from the group consisting of Ce, Pr, Nd, Pm, Sm, Eu, Tb, Dy, Ho, Er, Tm, Yb and Lu where O<X<0.5 and 1.75<Y<2. A preferred embodiment is wherein Re is Nd.

Abstract: This invention provides a metallic article with a metallic substrate having a thermal barrier ceramic coating on its surface, the ceramic coating comprising a plurality of first layers of about 6 to 8 wt % yttria stabilized zirconia alternating with a plurality of second layers of about 18 to 22 wt % yttria stabilized zirconia. The alternating layers can be distinct layers or gradient layers.