Partially stabilized zirconia (8Y2O3-ZrO2) coatings were studied as thick thermal barrier coatings (TTBCs) for diesel engine applications. To improve the hot corrosion resistance of TTBCs the 1 mm thick yttria stabilized zirconia coating was densified with aluminum phosphate based sealant. Combined with better hot corrosion resistance other benefits obtained with sealing treatment are improved adhesion as well as increased mechanical properties of the ceramic layer. Three aluminum phosphate based sealants were investigated with varying viscosity level. Different sealant viscosities were used to optimize the level of sealant penetration into the coating. Sealant penetration and the violence of the reaction were determined by XRD, SEM/EDS and optical microscopy. The hardness profile from bond coat to the surface of the top layer was determined. Coating microstructure and phase structure were characterized by optical microscopy and by X-ray diffraction. Microhardness and porosity were determined. Residual stress states were measured by X-ray based stress analyzer. Bond strength of the coatings was determined with tensile test equipment. To simulate the diesel engine combustion conditions, hot corrosion tests were performed for the sealed TTBCs. Hot corrosion resistance of the coating was tested in isothermal exposure of 60Na2SO4 - 40V2O5 melt for 48 hours at 600 °C.

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