Thermal Shock and Corrosion Resistant Ceramic Material Based on a Zirconia-Free Refractory Oxide and Process for Its Preparation

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This patent describes a new type of ceramic material that is free of zirconium dioxide and is highly resistant to both thermal shock and corrosion. The core innovation is a sintered matrix of refractory oxide (such as alumina, spinel, or mullite), which is engineered to have specific microstructural zones (based on titanium and zirconium oxides) that greatly improve its properties. The method of producing this material allows for precise control of porosity and microcracks to enhance thermal shock resistance, flexibility, and stability. The material is suitable for extreme environments due to its robust thermal, mechanical, and chemical stability.

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• Hot gas filtration systems, such as particle filters for diesel engine exhausts.
• Catalytic converter substrates for automotive and industrial exhaust systems.
• Heat and/or sound insulation layers or coatings in industrial applications.
• Porous filters in the chemical industry for aggressive or high-temperature environments.
• Components in metallurgy (e.g., pouring spouts, nozzles) for handling molten metals.
• Bioceramic implants or prosthetic devices where toughness and elasticity are crucial.
• Substrates or intermediate layers in multi-layer technical ceramics to reduce thermal mismatch.

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• Exceptional resistance to rapid temperature changes (thermal shock), reducing risk of failure or cracking in demanding applications.
• High corrosion resistance, especially important in harsh chemical or industrial environments.
• Adjustable mechanical properties—lower elastic modulus approaches that of bone, improving toughness and potential biocompatibility.
• Stable, controlled porosity for use in filtration applications, leading to effective high-temperature or high-velocity gas filtering.
• The absence of zirconium dioxide reduces material cost and prevents issues linked to its destabilization or environmental concerns.
• The material can be tailored for both dense (structural) and porous (filtering or insulating) applications.
• Improved compatibility between substrate and coating layers in advanced ceramic systems, reducing stress and risk of delamination.

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Patent Abstract

Ceramic material based on a zirconium dioxide-free oxide resistant to thermal shocks and corrosion, process for producing the same and its use. Shaped or unshaped products for the metallurgical industry, automobile industry, glass and cement industry and chemical industry can be produced from this ceramic material. According to the invention, the ceramic material resistant to thermal shocks and corrosion comprises a sintered matrix with a proportion of at least 90 % by weight of a dissolved zirconium dioxide-free refractory oxide, the matrix containing fissures formed in situ enclosing oxide zones, a ZrO2-rich zone with a positive coefficient of thermal expansion being at least partially enveloped by a TiO2-rich zone having a negative coefficient of thermal expansion or by a ZrO2-TiO2-Al2O3-mixed zone having a low coefficient of thermal expansion lower than that of the ZrO2-rich zone. Aluminium oxide and/or magnesium aluminate Spinel and/or mullite are used as refractory, zirconium dioxide-free oxide. Having a coefficient of thermal expansion of more than 7 10-6/K and a very low modulus of elasticity lower than 30 Gpa, the claimed material is suitable for a wide range of applications, in particular for hot gas particle filters, thermostable and corrosion-resistant catalytic converter substrates, as well as for filters and bioceramics.