A method and superalloy component for depositing a layer of material onto
gas turbine engine components by atomic layer deposition. A superalloy
component may have a ceramic thermal barrier coating on at least a
portion of its surface, comprising a superalloy substrate and a bonding
coat; and aluminum oxide (Al.sub.2O.sub.3) layer may be deposited on top
of an yttria-stabilized zirconia layer and form a bonding coat by atomic
layer deposition. The yttria-stabilized zirconia layer may have a
plurality of micron sized gaps extending from the top surface of the
ceramic coating towards the substrate and defining a plurality of columns
of the yttria-stabilized zirconia layer. Also, atomic layer deposition
may be used to lay an aluminum oxide (Al.sub.2O.sub.3) layer over a
tantalum oxide (Ta.sub.2O.sub.5) layer on a silicon-based substrate.
Using atomic layer deposition to coat the gas turbine engine components
permits conformal coating of the columnar surface to permit gap expansion
and contraction without sintering of the columnar surface or spalling of
the coating, and form an oxidation resistant bonding coat.