Investigation of reactions between vanadium oxide and plasma-sprayed yttria-stabilized zirconia coatings

The phase evolution occurring during the reaction between corrosive V₂O₅ (T_m = 690 °C) and a plasma-sprayed 7 wt.% Y₂O₃-ZrO₂ (YSZ) coating from 700 to 900 °C has been investigated in situ by X-ray diffraction. The temperature and time of interaction between the V₂O₅ and YSZ coating determines the phases observed. Between 700 and 750 °C, reaction products of ZrV₂O₇ and YVO₄ were observed within minutes of reaching the test temperature. m-ZrO₂ was observed after 220 and 60 min at 700 and 750 °C, respectively. The simultaneous formation of both ZrV₂O₇ and YVO₄ at the beginning of the reaction along with the delay of the m-ZrO₂ formation suggests similar reactivity between both Zr and Y with V₂O₅. The weight percent of the ZrV₂O₇ phase began to diminish after 150 and 60 min at 700 and 750 °C, respectively. For reaction temperatures of 800 and 900 °C, there is a rapid decrease in the amount of t′-ZrO₂ and a rapid increase in the amount of m-ZrO₂ with reaction time. YVO₄ was also observed at these reaction temperatures. SEM and TEM microstructural observations confirmed the phases detected from the in situ XRD experiments. Reactions between YSZ and V₂O₅ suggest that the formation of a liquid phase due to the high solubility of both zirconia and yttria in vanadia is the dominate mechanism that damages the coating. The thermal conductivity of a plasma-sprayed YSZ coating reacted with up to 1 wt.% V₂O₅ did not significantly change due to the small volume affected.