The application and typical failure of plasma-sprayed thermal barrier coatings (TBCs) and the growth rate control of thermal growth oxides (TGO) in the case were discussed. According to the idea of the reducing thermal expansion mismatch, a new TBCs with a double-layer bond coat was designed and prepared. The TGO growth and durability of TBCs were characterized. The TGO grew nearly exponentially, which was much lower than that of traditional TBCs. Compared with the traditional TBCs, the durability increased by about 100%.
