Thick Nanostructured PSZ-NiCoCrAlY graded TBCs were got byair plasma spraying. The results reveal the morphology and phase transformation of TBCs by means of SEM and XRD. The plasma spray process results in a characteristic layered structure consisting of lamellae, unmelted nano-particles and an inter-lamellar porosity. The test results of thermal shock show that the graded coatings have different failure behavior. The failure mode was the spallation of top coat due to thermal stress. It has been found that the lamella consists of nanoscale columnar grains parallel to the spraying direction.
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