High performance thermal barrier coating was composed of bond coat NiCrAlY and top coat nanostructural zirconia. NiCrAlY coating was fabricated by high velocity oxygen fuel spraying, while nanostructural zirconia coating was fabricated by atmosphere plasma spraying. Both processes were optimized by means of orthogonal design. The morphology and property of the thermal barrier coating prepared by these optimal processes were analyzed. The results indicate that the porosities of NiCrAlY bond coat and nanostructural zirconia top coat are less than 2% and about 15% , respectively. The tensile samples are bonded using solid membrane adhesive. The bond strength value of the sample measured by tensile adhesion test is about 30. 4 MPa. The thermal shock test is performed by water quenching method. The sample is heated in furnace at 1100 益and then quenched into ambient water. The thermally grown oxide of thermal barrier coating after 50 cycles is compact Al2 O3 .