Abstract
This work is aimed to study effect of alumina coating on the partially stabilized zirconia alumina
composite (YPSZ/ Al2
O3
) on the microstructure, phase transformation and hot corrosion performance of eutectic molten salt V2
O5
+ 45 wt% Na2
SO4
and comparing with conventional YSZ.Both
the pure alumina and YPSZ are sprayed by using atmospheric plasma spray APS. Hot corrosion
for composite is done by exposing the samples to an isothermal air furnace testing at900 °C for
different exposure times of40 and 80 hours. Upper surface plan views of the coatings are examined using SEM. The hot corrosion test products are determined using EDS, EPMA and XRD. The
results indicate the higher hot corrosion resistance of YSZ/ Al2
O3
composite coatings compared
with conventional YSZ sprayed coatings. Degradation of YSZ due to the presence of eutectic
harsh salt attack is occurred by destabilization of yttria from the zirconia yttria coatings. This will
lead to disrupt transformation from metastable tetragonal phase (t’) to monoclinic phase (m). the
corrosion products of YVO4
produce by leaching process. During exposure the composite to the
molten salt the Al2
O3
is reacted with vanadate to form a low-melting liquid eutectic phase, leading to dissolution of Al2
O3
in molten NaVO3
Na2
O–V2
O5
–Al2
O3
. The pores and cracks within the
YSZ coating are filled with Al2
O3
. The absences of leaching of yttria in under layer for composite
coatings is related to the absence of pockets of open porosity and cracks due to elimination after
alumina layer applied.
composite (YPSZ/ Al2
O3
) on the microstructure, phase transformation and hot corrosion performance of eutectic molten salt V2
O5
+ 45 wt% Na2
SO4
and comparing with conventional YSZ.Both
the pure alumina and YPSZ are sprayed by using atmospheric plasma spray APS. Hot corrosion
for composite is done by exposing the samples to an isothermal air furnace testing at900 °C for
different exposure times of40 and 80 hours. Upper surface plan views of the coatings are examined using SEM. The hot corrosion test products are determined using EDS, EPMA and XRD. The
results indicate the higher hot corrosion resistance of YSZ/ Al2
O3
composite coatings compared
with conventional YSZ sprayed coatings. Degradation of YSZ due to the presence of eutectic
harsh salt attack is occurred by destabilization of yttria from the zirconia yttria coatings. This will
lead to disrupt transformation from metastable tetragonal phase (t’) to monoclinic phase (m). the
corrosion products of YVO4
produce by leaching process. During exposure the composite to the
molten salt the Al2
O3
is reacted with vanadate to form a low-melting liquid eutectic phase, leading to dissolution of Al2
O3
in molten NaVO3
Na2
O–V2
O5
–Al2
O3
. The pores and cracks within the
YSZ coating are filled with Al2
O3
. The absences of leaching of yttria in under layer for composite
coatings is related to the absence of pockets of open porosity and cracks due to elimination after
alumina layer applied.
Keywords
yttria partially stabilized zirconia; Plasma sprayed coatings; hot corrosion; vanadate-sulfate.