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Gas turbines rely on thermal barrier coating (TBC) to thermally insulate thenickel-based superalloys underneath during operation; however, current TBCs,yttria stabilised zirconia (YSZ), limit the operating temperature and henceefficiency. At an operating temperature above 1200{\deg}C, YSZ is susceptibleto failure due to phase instabilities and CMAS (Calcia-Magnesia-Alumina-Silica)attack. Gadolinium zirconates (GZ) could overcome the drawback of YSZ,complementing each other with the multi-layer approach. This study introduces anovel approach utilising axial suspension plasma spray (ASPS) and axialsolution precursor plasma spray (ASPPS) to produce a double-layer and atriple-layer TBCs with improved CMAS resistance. The former comprisedsuspension plasma sprayed GZ and YSZ layers while the latter had an additionaldense layer deposited through a solution precursor to minimise the columnargaps that pre-existed in the SPS GZ layer, thus resisting CMAS infiltration.Both coatings performed similarly in furnace cycling test (FCT) and burner rigtesting (BRT). In the CMAS test, triple-layer coating showed better CMASresistivity, as evidenced by the limited CMAS infiltration observed on thesurface.

Multilayer GZ/YSZ Thermal Barrier Coating from Suspension and Solution Precursor Plasma Spray