In this paper, ZrSiO4 and Y2O3 doped ZrSiO4 coatings were successfully prepared by atmospheric plasma spraying. The microstructure, mechanical properties and sintering behavior at 1300 °C of coatings were investigated. The results showed that plasma-sprayed ZrSiO4 coating was mainly composed of ZrSiO4, t-ZrO2, a small amount of m-ZrO2 and amorphous SiO2 phases, while the ZrSiO4-5%Y2O3 coating contained c-ZrO2, a small amount of ZrSiO4 phase and amorphous SiO2. Compared with ZrSiO4 coating, Y2O3 doping slightly improved the hardness and fracture toughness of ZrSiO4-5%Y2O3 coating. After sintered at 1300 °C for 48 h, (t,m)-ZrO2 reacted with amorphous SiO2 to form new ZrSiO4 phase in plasma-sprayed ZrSiO4 coating accompanied by volume shrinkage, resulting in a large number of pores and cracks in the coating. In contrast, c-ZrO2 phase and ZrSiO4 phase were the main phases in the ZrSiO4-5%Y2O3 coating. The addition of Y2O3 helped the ZrO2 in the coating to maintain the cubic phase (c-ZrO2), which improved the high-temperature phase stability of ZrO2.