Patent ID: 8084086

Claim:
A method for forming a thermal barrier coating system in communication with at least a portion of at least one substrate, said method comprising: depositing a bond coat on at least a portion of said substrate; depositing a thermal barrier coat on said bond coat; and depositing a second bond coat on said thermal barrier coat, said second bond coat comprising a material having a coefficient of thermal expansion (CTE) of greater than 10×10 −6 ; wherein said bond coat, said thermal barrier coat, and second bond coat are deposited using at least one of the following deposition techniques comprising: directed vapor deposition (DVD), evaporation (thermal, RF, laser, or electron beam), reactive evaporation, sputtering (DC, RF, microwave and/or magnetron), reactive sputtering, electron beam physical vapor deposition (EF-PVD), ion plasma deposition (IPD), low pressure plasma spray (LPPS), high velocity oxy-fuel (HVOF), vapor deposition, cluster deposition, cathodic arc deposition, or jet vapor deposition, or any combination thereof.