Process for Producing a Flame- or Plasma-Sprayed Thermal Shock and Corrosion-Resistant Ceramic Coating Based on Al2O3-TiO2-ZrO2

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This patent describes a process for manufacturing a ceramic coating made from a mixture of aluminum oxide, titanium oxide, and zirconium oxide, which is applied to a substrate using flame or plasma spraying. The coating is engineered to be highly resistant to thermal shock and corrosion. The process includes preparing powders with specific proportions and grain sizes, blending them with auxiliary materials, and forming workpieces for the spraying process. The resulting coatings develop specialized microstructures that enhance durability under extreme thermal conditions.

Use CasesContent extracted from patent full text and abstract with AI.

• Protective coatings on components in turbines and engines exposed to high temperatures
• Thermal barrier layers for industrial furnaces or reaction vessels
• Coatings for components in power generation plants, such as gas turbines or boilers
• Corrosion-resistant linings in chemical processing equipment
• Wear and thermal protection for automotive or aerospace parts

BenefitsContent extracted from patent full text and abstract with AI.

• Excellent thermal shock resistance, reducing the risk of coating failure under rapid temperature changes
• Improved corrosion resistance for components exposed to harsh chemical environments
• Durable protection extends the service life of industrial and mechanical parts
• Potential to reduce maintenance costs and downtime by minimizing surface deterioration
• Customizable microstructure for optimized performance via controlled composition and process parameters

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Patent Abstract

The process comprises preparing slurry, shapeable mass or granule from an external mixture by the addition of dispensing agent and/or further auxiliary materials of organic and/or inorganic basis and then forming a workpiece by casting process, extrusion or pressing. A magnesium oxide partially-stabilized or fully-stabilized zirconium oxide powder with a portion of (5-15 wt.%) and a grain size of (0.05-50 mu m) and a titanium oxide powder with a portion of (up to 5 wt.%) and a grain size of (0.05-50 mu m) are added to an aluminum oxide powder with a portion of (80-90 wt.%). The process comprises preparing slurry, shapeable mass or granule from an external mixture by the addition of dispensing agent and/or further auxiliary materials of organic and/or inorganic basis and then forming a workpiece by casting process, extrusion or pressing. A magnesium oxide partially-stabilized or fully-stabilized zirconium oxide powder with a portion of (5-15 wt.%) and a grain size of (0.05-50 mu m) and a titanium oxide powder with a portion of (up to 5 wt.%) and a grain size of (0.05-50 mu m) are added to an aluminum oxide powder with a portion of (80-90 wt.%) and a grain size of (0.05-50 mu m), where usable workpieces are produced from these mixtures for thermal spraying or plasma spraying. The aluminum oxide-titanium oxide-zirconium oxide powder mixtures are introduced on a substrate or an irrecoverable core by thermal spraying or plasma spraying, so that a completely formed primary crack pattern develops during thermal spraying and during the thermal spraying begins and during the use, crystalline and amorphous phases develop, magnesium oxide stabilizer of the zirconium oxide spinel phases and/or magnesium titanate is formed, the zirconium dioxide is destabilized and/or zirconium titanate and/or aluminum titanate are formed, which guide in sum to subcritical crack origins in the ceramic matrix and for the formation of secondary crack pattern and improve the thermal shock resistance. The temporary auxiliary material on tenside-, polyacrylate- and/or flour-basis is added to the inorganic fire-proof mixture consisting of aluminum oxide, magnesium oxide partially-stabilized or fully-stabilized zirconium oxide and titanium oxide for controlling the open porosity.