Abstract
In order to improve the hot corrosion resistance of yttria‐stabilized zirconia (YSZ), an Al2O3 overlay has been deposited on the surface of YSZ by electron‐beam physical vapor deposition. Hot corrosion tests have been performed on the YSZ coatings with and without an Al2O3 overlay in the molten salt mixture (Na2SO4+0–15 wt% V2O5) at 950°C. The presence of V2O5 in the molten salt exacerbates degradation of both the monolithic YSZ coating and the composite YSZ/Al2O3 system. The formation of a low‐melting Na2O–V2O5–Al2O3 liquid phase is responsible for degradation of the Al2O3 overlay. The Al2O3 overlay acts as a barrier against the infiltration of the molten salt into the YSZ coating during exposure to the molten salt mixture with <5 wt% vanadate.
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