Improvement of alkali corrosion resistance of mullite ceramics at high temperature by depositing Ca_0.3Mg_0.2Zr₂(PO₄)₃ coating

Ca_0.3Mg_0.2Zr₂(PO₄)₃ coating was deposited on the mullite ceramic to improve its alkali corrosion resistance at high temperatures, using sol–gel method and dip-coating technique. The phase composition and microstructure of the coating were characterized by X-ray diffraction and scanning electron microscopy (SEM). Results show that homogeneous, dense and single-phase Ca_0.3Mg_0.2Zr₂(PO₄)₃ coating was successfully deposited on mullite ceramics. SEM microstructural examination revealed the excellent bonding between Ca_0.3Mg_0.2Zr₂(PO₄)₃ coating and mullite ceramics. The effectiveness of the prepared coating to improve the alkali corrosion resistance of mullite ceramics was assessed through the measurements of mass loss and flexural strength degradation after 96 h and longer exposure time at alkali corrosion condition at 1000 °C. A significant enhancement of the alkali corrosion resistance for Ca_0.3Mg_0.2Zr₂(PO₄)₃-coated mullite samples was observed. Therefore, the effectiveness of the Ca_0.3Mg_0.2Zr₂(PO₄)₃ material as protection coating for mullite ceramic is confirmed.