THERMAL BARRIER COATING SYSTEM WITH POROUS TUNGSTEN BRONZE STRUCTURED UNDERLAYER

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A system of layers in a protective coating (20) for a substrate (22), including at least an outer thermal barrier layer (32) and a tungsten bronze structure ceramic underlayer (30) that reduces spalling of the outer layer. The range of materials for the underlayer includes ceramics of the form Ba6-3m Re8+2m Ti18 O54, where 0 < m < 1.5, and Re is any rare earth element or mixture thereof. These underlayer materials reduce spalling of the thermal barrier layer, and thus extend the life of the coating system. In some embodiments, materials for the outer thermal barrier layer may include Yttria-stabilized Zirconia (YSZ) or ceramics with lower thermal conductivity than YSZ. A segmented YSZ layer (26) is provided in some embodiments for additional thermal expansion compliance.