To improve the hot corrosion resistance of YSZ thermal barrier coatings, a 25 (micro)m and a 2 (micro)m thick Al(sub 2)O(sub 3) overlay were deposited by HVOF thermal spray onto to the surface of YSZ coating. Oxidation at high temperature and hot corrosion tests showed that Al(sub 2)O(sub 3) overlay deposited on the YSZ TBCs surface can not only reduce the hot corrosion rate, but also significantly prevents the bond coat from oxidation.