Patent ID: 7955708

Claim:
A high-purity coating structure that is suitable for high temperature cycling applications, said coating structure formed by the process of: providing a material consisting essentially of about 4 to 20 weight percent of a stabilizer of one or more rare earth oxides, and a balance of at least one of zirconia (ZrO 2 ), hafnia (HfO 2 ) and combinations thereof, wherein the zirconia (ZrO 2 ) and/or hafnia (HfO 2 ) is partially stabilized by the stabilizer, and wherein the total amount of impurities is less than or equal to 0.15 weight percent; and spraying said material onto a metal substrate using a vapor deposition process at pressures between 1 mPa and 1 kPa, so as to form a coating with ceramic columns and gaps between the columns, wherein the sprayed high-purity coating structure comprises the ceramic columns and gaps between the columns, and wherein the amount of impurities is less than or equal to: about 0.01 weight percent silica, about 0.01 weight percent titania, about 0.01 weight percent hematite, about 0.025 weight percent calcic, and about 0.025 weight percent magnesia.