general requirements for an effective TBC can be summarize as needing: 1) a high melting point.

2) no phase transformation between room temperature and operating temperature. 3) low thermal
conductivity. 4) chemical inertness. 5) similar thermal expansion match with the metallic
substrate. 6) good adherence to the substrate. 7) low sintering rate for a porous microstructure.

Thermal barrier coatings typically consist of four layers: the metal substrate, metallic bond
coat, thermally-grown oxide (TGO), and ceramic topcoat.

The bond coat is an oxidation-resistant metallic layer which is deposited directly on top of the
metal substrate. It is typically 75-150 μm thick and made of a NiCrAlY or NiCoCrAlY alloy,
though other bond coats made of Ni and Pt aluminides also exist. The primary purpose of the
bond coat is to protect the metal substrate from oxidation and corrosion, particularly from
oxygen and corrosive elements that pass through the porous ceramic top coat.

These growth stresses and lattice mismatch stresses, which increase with increasing cycling
number, lead to plastic deformation, crack nucleation, and crack propagation, ultimately
contributing to TBC failure after many cycles of heating and cooling. For this reason, in order to
make a TBC that lasts a long time before failure, the thermal expansion coefficients between all
layers should match well.

Most of the superalloys that are used in gas turbine components develop oxidation and corrosion
while in operation. It is essential that any of these contaminants are removed completely,
including remnants of the previous coating.

 care should be taken when grit blasting or blending, to minimize any removal of the original
substrate.  To identify any remaining areas of oxidation or residual coating, components are heat
tinted. If contaminants remain, the process repeats until suitable results are achieved.

Final pre-coat quality control checks should be completed, including dimensions, flow checks
and inspections for defects, using penetrant if necessary. Coatings will only bond properly if
there are no gaps or cracks in the substrate; any such flaws will cause rapid deterioration of a
new coating.