A method of depositing a catalytically reactive coating to a substrate
including selecting a target light off temperature for a predetermined
catalytic combustion environment, selecting a thermal barrier coating
composition, selecting a catalytic material and codepositing the thermal
barrier coating composition and the catalytic material onto the substrate
in proportions selected to produce the target light off temperature when
exposed to the combustion environment. The method may include controlling
the codepositing step to cause the thermal barrier coating composition to
interact with the catalytic material to produce a phase having a light
off temperature different from the respective light off temperatures of
the thermal barrier coating composition and the catalytic material. A
catalyst element may include a substrate and a first layer comprising a
thermal barrier coating composition and a catalytic material throughout
its depth disposed over a first portion of the substrate. Other portions
of the catalyst element may have a second layer consisting of a catalytic
material and a third layer consisting of a thermal barrier coating
composition depending on a stage of combustion with a combustion
environment.