Hot-dip Al–Si alloy coating is an effective corrosion resistant coating for modern steel. However, the molten Al–Si alloy corrosion has become one of the problems to be urgently solved for sink rollers and their spare parts in the hot-dip Al–Si alloy production line. In this work, yttria partially stabilized zirconia (YSZ)/NiCrAlY protective coating was fabricated by air plasma spraying. The influence of spraying power on the microstructure and mechanical properties of the YSZ coating, and its corrosion behavior in Al–Si melt at 700℃ was also investigated. The results showed that YSZ coating presented a typical layered structure with lath-shaped and interlayer columnar grains. The interlayer columnar grains tended to grow up with the increase of spraying power from 37 kW to 46 kW. YSZ coating was mainly composed of t-ZrO2 phase and small amount of m-ZrO2 phase, and spraying power had no obvious influence on the phase compositions. The YSZ coating with 40 kW spraying power had relatively high microhardness and adherence strength values (642.4 HV0.3 and 62 MPa). Additionally, no reaction layer was formed at the interface between YSZ coating and Al–Si melt at 700℃ for 240 h, and the Si and Al elements in the molten Al–Si alloy also did not infiltrate into the YSZ coating, suggesting that YSZ/NiCrAlY protective coating could effectively prevent Al–Si alloy melt on the surface of coating.