Zyp Coatings, Inc.

Orpac, Inc.

The United States of America as Represented by the United States Energy

Ztp Coatings

Cressie E Holcombe, Jr

Lloyd R Chapman

William Brent Webb

Douglas D Smith

Lloyd A Chapman

Bulk paint and ceramic powder systems, methods of forming same, and methods of forming a flexible ceramic coating on a metal substrate are disclosed. The systems may include a ceramic composition having between 2 to 30 weight percent of an alkali metal oxide, such as KO, NaO, and LiO or mixtures thereof, between 10 to 74 weight percent SiO, and between 23 to 79 weight percent BO. Additives that are nonwetting with molten metals, such as boron nitride, provide durable coatings for metal processing operations. The ceramic composition may include less than 5 weight percent additional metal oxides. The bulk paint system further may include water and a cellulosic suspension agent to form a bulk paint. The ceramic powder system may be processed to form a uniform powder. The bulk paint or uniform powder may be applied to a metal substrate, such as a ferrous metal substrate, dried, and heated to form a flexible coating on the metal substrate.

Flexible ceramic coatings for metals and methods of making same

A lubricant for the topical application to objects that will contact various forms of water, e.g., liquid, snow, ice, or mixtures thereof, to reduce friction and thereby increase speed, glide and maneuverability. The lubricant consists essentially of hexagonal boron nitride and a binder of single or mixed oxides or organics, the boron nitride content (after drying) being from about 36 wt. % to about 99 wt. %. Binders of particular interest are water-based colloidal aluminum oxide and colloidal silicon dioxide. This lubricant is suitable for topical applications in a thin layer to various sports objects, such as skis, snowboards, ice skates, snowmobiles, toboggans, sleds, boats, etc., where reduced friction, and thus higher speed, glide and maneuverability is desired. Although a solid stick form (by drying or pressure-less sintering) is preferred, the lubricant can be in the form of a paste or a powder. Further, this lubricant can be incorporated into waxes of the type previously used for friction reduction to obtain the benefit of both.

Surface lubricant for objects contacting forms of water and method of

A relatively chemically inert ceramic material produced from a clay-like mixture of boron nitride powder and aluminum oxide, where the aluminum oxide is derived from colloidal aluminum oxide, peptized aluminum oxide, or a dissolved aluminum salt. The clay-like mixture can be dried in a near net shape without cracking and then pressure-less sintered, or bulk dried. Alternatively, pressure-less sintered bodies can be easily machined to a given shape. The ceramic has properties very similar to those of boron nitride in that it resists damage from molten materials, has a high electrical resistance, has high strength at ambient and elevated temperatures, etc. A typical pressure-less sintered body is formed from a clay made with finely-divided boron nitride mixed with at least one of the listed sources of aluminum oxide such that the final sintered composition contains about 85 wt. % boron nitride.

Boron nitride-containing bodies and method of making the same

Paintable compositions for the formation of coatings on, for example, iron-based metals that, when dry, inhibit oxidation, decarburization and other similar reactions when the metal is heated to temperatures of about 2300 degrees F. (1300 degrees C.). The preferred binder portion of the composition, which in itself provides reasonable protection when dry, consists essentially of an aqueous colloidal silica solution together with an aqueous alkali hydroxide and oxides selected from the transition metals cobalt, chromium, iron, manganese, nickel, titanium, zinc and zirconium. The composition is benefitted by the addition of Sb.sub.2 O.sub.3. The preferred ranges of composition are described as well as certain additives to enhance performance under various conditions. These include the use of filler materials, as well as high expansion additives when the coating is to withstand temperatures recycling of the metal, and low expansion additives to enhance spallation following a single heating. The coating is useful for other metal and ceramic substrates to prevent or reduce deleterious damage to the surface at high temperatures.

Paintable composition for protecting metals and ceramics during thermal

A composition to produce an adherent and water insoluble deposit on substrate surfaces. A coating material for these surfaces is described which can be applied at any temperature up to at least 2,000 degrees Fahrenheit, with the resultant deposit (after drying) being highly adherent and water insoluble. This coating has a liquid phase formed from at least water, a pre-reacted lithium silicate, and unreacted lithium hydroxide monohydrate. Preferably, the liquid phase contains a dispersent in the form of a clay, for example. Typically the pre-reacted Li.sub.2 O-SiO.sub.2 has a SiO.sub.2 :Li.sub.2 O molar ratio of about 4.6:1, and the unreacted LiOH.H.sub.2 O provides from 1/3 to 2/3 the total lithium oxide content, giving a final SiO:Li.sub.2 O molar ratio of the composition of from about 1.71:1 to about 2.97:1. To this liquid phase is added a suitable pigment or other refractory material, at about 6-80 wt % based upon the liquid phase. A range of compositions is discussed as well as typical results. This includes graphite, oxides, borides, nitrides, carbides, sulfides, metals and mixtures thereof. The particular refractory material must be stable in the highly basic condition of the liquid phase.

Binder/suspension composition yielding water insolubility alone or with

A binder/suspension liquid for use with refractory compounds and the like. Oxidation prevention coatings for up to at least 1000 degrees Centigrade are described. Both a graphite non-conductive and a conductive coating are described for use in coating graphite crucibles, graphite electrodes, and the like. Typical compositions utilize a binder/suspension liquid phase in an amount from about 40 to about 55 wt. % of the total paintable mixture. This binder/suspension liquid phase is formed by intimately mixing colloidal silica solution, mono-aluminum phosphate solution and alcohol. The non-conducting embodiment of the graphite coating is produced by mixing finely divided boric acid and silicon carbide with the binder/suspension liquid phase. The preferred conductive coating substitutes a mixed TiC-SiC for the SiC of the non-conductive embodiment. The resultant material is very stable (i.e., does not settle), is paintable upon the graphite, and is easily dried at or near room temperature. A few thin coats, with drying between applications, totaling only about 0.15 to about 0.23 mm prevents detrimental oxidation through several cycles to at least 1000 degrees C. Other applications of the binder/suspension agent are discussed.

Binder/suspension composition and method of preparation thereof

A composition to produce an adherent and water insoluble deposit on substrate surfaces. An ink or other coating material for these surfaces is described which can be applied at any temperature up to at least 2,000 degrees Fahrenheit, with the resultant deposit (after drying) being highly adherent and water insoluble. As an ink, this composition is useful to produce bar codes on metals to identify the composition, heat treatment, customer, sections for other processing, etc. This ink (coating) has a liquid phase formed from at least water, a pre-reacted lithium silicate, and unreacted lithium hydroxide monohydrate. Preferably, the liquid phase contains a dispersent in the form of a clay, for example. Typically the pre-reacted Li.sub.2 O-SiO.sub.2 has a SiO.sub.2 :Li.sub.2 O molar ratio of about 4.6:1, and the unreacted LiOH.multidot.H.sub.2 O provides from 1/3 to 2/3 the total lithium oxide content, giving a final SiO:Li.sub.2 O molar ratio of the composition of from about 1.71:1 to about 2.97:1. To this liquid phase is added a pigment, typically TiO.sub.2 or MnO-Fe.sub.2 O.sub.3 at about 12-60 wt % based upon the liquid phase. A range of compositions is discussed as well as typical results.

High temperature ink with ambient temperature utility and method of

An oxidation prevention coating for graphite up to at least 1000 degrees Centigrade. Both a non-conductive and a conductive coating are described for use in coating graphite crucibles, graphite electrodes, and the like. All of the compositions utilize a binder/suspension liquid phase in an amount from about 40 to about 55 wt % of the total paintable mixture. This binder/suspension liquid phase is formed by intimately mixing colloidal silica solution, mono-aluminum phosphate solution and ethyl alcohol. The non-conducting embodiment of the invention is produced by mixing finely divided boric acid and silicon carbide with the binder/suspension liquid phase. The preferred conductive coating substitutes a mixed TiC-SiC for the SiC of the non-conductive embodiment. The resultant material is very stable (i.e., does not settle), is paintable upon the graphite, and is easily dried at or near room temperature. A few thin coats, with drying between applications, totaling only about 0.15 to about 0.23 mm prevents detrimental oxidation through several cycles to at least 1000 degrees C.

Oxidation prevention coating for graphite

Oxide compositions containing niobium pentoxide and an oxide selected from the group consisting of hafnia, titania, and zirconia have electrical conductivity characteristics which vary greatly depending on the oxygen content.

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Knox County, TN, United States of America

Cressie E Holcombe, Jr