Segmented thermal barrier coatings were produced by plasma spraying hollow and solid ZrO2-8 Wt.% Y2O3 powders. The solid powder (SP) had greater capability of producing segmentation cracks in coating compared with the hollow powder (HP). High substrate temperature (T-S) gave rise to an increased segmentation crack density (DJ. The segmentation crack network was still stable even after sintering at 1300 degrees C for 15 h. The microcracks that are mainly attributed to delaminations between splats had a negative effect on the origin and propagation of segmentation cracks. (c) 2005 Elsevier B.V. All rights reserved.