To improve the quality of ceramic coatings, the methods described herein propose to increase the amount of vertical microcracking present within the coating microstructure.

As a substrate 34 comprising a deposited bond coat layer 30 and a deposited ceramic coating layer 36 moves in the direction of an arrow 40, a heat source 42 elevates the surface temperature of a low thermal gradient area 50 to form a surface heating area 52, and induces a thermal gradient causing the surface to expand and close existing cracks therein. After a deposition device 44 deposits another ceramic layer 38, as a substrate 34 continues moving in the direction of arrow 40 and away from heat source 42 and deposition device 44, the coating layers 30, 36, 38 begin cooling and are shrunk. Vertical cracks begin propagating to the surface that is exposed to atmosphere to relieve tensile stresses as the temperatures between the newly deposited coating layer 38 and existing coating layers 30, 36 equilibrates.