Hot corrosion behavior of NdYbZr2O7 exposed to V2O5 and Na2SO4 + V2O5 molten salts

Abstract In order to evaluate the application prospects of NdYbZr2O7 as a novel TBC material, NdYbZr2O7 ceramic was synthesized via a solid-state reaction sintering method, and its hot corrosion behavior exposed to V2O5 and Na2SO4 + V2O5 molten salts at 900 °C, 1000 °C, and 1100 °C was comparatively investigated. For the V2O5 salt, the primary corrosion products were granular (Nd,Yb)VO4 as well as cube-like m-ZrO2. The corrosion layer consisted of two distinct layers, one of which was Zr-rich layer and another was V-rich layer. In the case of Na2SO4 + V2O5, NaVO3, as an intermediate product, played an important role in dissolving the NdYbZr2O7 ceramic. Herein, the (Nd,Yb)VO4 exhibited a rod/plate-like morphology, which could be attributed to the synergistic effect of low driving force and low nucleation rate. Since the molten salt infiltration rate was superior to the pore filling rate throughout the hot corrosion, the thickness of corrosion layer increased with the rise of temperature. The hot corrosion mechanisms of NdYbZr2O7 ceramic in various molten salts were discussed based on the phase diagram, Lewis acid-base rule and chemical thermodynamics. On this basis, the NdYbZr2O7 coating was prepared by atmospheric plasma spray (APS) and it exhibits a higher corrosion resistance compared to YSZ coating.