An article having a spallation resistant TBC comprises a metal substrate, such as a high temperature superalloy, and a TBC, such as a coating of yttria stabilized zirconia. The TBC comprises a plurality of plasma-sprayed layers. The TBC has a coherent, continuous columnar grain microstructure, wherein at least one layer has a plurality of continuous columnar grains which have been extended by directional solidification into an adjacent layer. In a preferred embodiment, the coherent, continuous columnar microstructure comprises substantially all of the volume of TBC. A coherent, continuous columnar grain microstructure is also taught wherein at least some of the plurality of coherent, continuous columnar grains which comprise a TBC extend through essentially the entire thickness of the coating. A columnar crack pattern of cracks extending generally normal to the surface of the metal substrate is also developed within TBCs of the present invention in conjunction with the coherent, continuous columnar grain microstructures described.