The　hierarchical　porous　microsphere　is　a　promising　feedstock　for　thermal　barrier　coatings　(TBCs),　due　to　its　excellent　flowability,　high　compression　strength,　and　high　temperature　structure　stability.　This　study　aims　to　determine　the　formation　mechanism　of　the　coating　deposited　using　hierarchical　porous　microspheres.　For　the　(Sm0.2Gd0.2Dy0.2Er0.2Yb0.2)2Zr2O7　hierarchical　microsphere　sintered　at　1000　ºC　to　1550　ºC,　the　thermal　conductivity　increased　from　0.21　to　0.64　W/m·K,　the　compression　strength　increased　from　13　MPa　to　80　MPa.　The　hierarchical　porous　structure　can　inhibit　the　heat　flow　from　the　surface　to　interior,　resulting　in　the　low　melting　degree　in　the　plasma　jet.　Additionally,　the　coatings　exhibit　the　characteristics　of　nanostructured　coatings　and　hierarchical　porous　zones　inherited　from　the　microspheres,　as　evidenced　by　a　comparison　of　compression　strength　and　impact　strength　during　deposition.　The　as-sprayed　nanostructured　coating　shows　a　significantly　lower　initial　thermal　conductivity　of　0.33　W/m·K　at　1000　ºC　compared　to　the　conventional　coating.　©　2024　Elsevier　Ltd