Thermal barrier coatings (TBCs) have advantages of decreasing the surface temperature of aero-engine blades, improving oxidation resistance of blades, prolonging blades service lifetimes, and reducing fuel consumption of engines, which have been widely used for decades. A typical TBC system is composed of a metallic bond coat and a ceramic top coat. The former is usually made of MCrAlY (M:Ni, Co or Ni+C) and PtAl, and the latter is made of Y2O3 partially stabilized ZrO2 (YSZ). Metallic bond coats can be prepared by high velocity oxygen-fuel (HVOF) or atmospheric plasma spraying (APS) methods. APS bond coats have rough surfaces and good adhesion to the ceramic top coat, but their porosities are high and the cohesive force is relatively, while the HVOF ones have dense microstructure, excellent oxidation resistance, good adhesion to the substrate, but the surface roughness is low and the adhesion to the ceramic top coats is not high enough. Before, the preparation of ceramic top coats, the substrates with bond coats need vacuum heat treatment, which could promote to formation a thermally grown oxide (TGO) layer on the bond coat leading to enhanced oxidation resistance and interface bond strength. Usually, it is considered that the abnormal growth of the TGO layer is a key factor causing TBCs failure.