Zyp Coatings, Inc.

Equity Enterprises

Other

The United States of America As Represented by the United States

Orpac, Inc.

Ztp Coatings

Lloyd R Chapman

Cressie E Holcombe

Cressie E Holcombe, Jr

William Brent Webb

David R Masters

Walter G Northcutt, Jr

Steven R Schenck

Christopher W Ivey

Karl W Dersch

A carbon material is formed by heat-treating a carbonaceous material in a reaction mix of boron oxide or its precursors and ammonia-generating phases such as melamine or its like in a nitrogen atmosphere to temperatures of 1600 to 2000&#xb0; C. The surface of the carbonaceous material is transformed into a carbon material that is resistant to oxidation to temperatures of 900&#xb0; C., enabling machined components to be utilized for weeks at that temperature. The carbon material also is stable in inert or vacuum environments to temperatures in the range of 1500 to 2000&#xb0; C., enabling its use as aluminum evaporative boats and the like.

Carbon material and process of manufacturing

A carbon material is formed by heat-treating a carbonaceous material in a reaction mix of oxides of boron and boron nitride in a nitrogen atmosphere to temperatures of 1600 to 2000&#xb0; C. The surface of the carbonaceous material is transformed into a carbon material that is resistant to oxidation to temperatures of 900&#xb0; C., enabling machined components to be utilized for weeks at that temperature. The carbon material is also stable in inert or vacuum environments to temperatures in the range of 1500 to 2000&#xb0; C., enabling its use as aluminum evaporative boats and the like.

Surface hardened carbon material and process of manufacturing

A carbon material is formed by heat-treating a carbonaceous material in a reaction mix of boron oxide or its precursors and ammonia-generating phases such as melamine or its like in a nitrogen atmosphere to temperatures of 1600 to 2000&deg; C. The surface of the carbonaceous material is transformed into a carbon material that is resistant to oxidation to temperatures of 900&deg; C., enabling machined components to be utilized for weeks at that temperature. The carbon material also is stable in inert or vacuum environments to temperatures in the range of 1500 to 2000&deg; C., enabling its use as aluminum evaporative boats and the like.

A fully inorganic boron nitride paste, containing 80 to 94% of a boron nitride paint and 6 to 20% of ceramic fibers, is provided to allow the process of manufacturing boron nitride &ldquo;shell&rdquo; coatings of 0.0313 to 0.25 inch onto ceramic substrates chosen from a wide range of densities. De-clumping of the ceramic fibers such that fiber lengths are greater than 100 micrometers and clumps are less than {fraction (3/32)} inch improves boron nitride &ldquo;shell&rdquo; layer uniformity. Boron nitride content of greater than 36 wt. % (or about 50 vol. %) in the boron nitride &ldquo;shell&rdquo; provides ceramic structures with a matrix of boron nitride that provides long-term nonwetting behavior for molten nonferrous metals.

Boron nitride paste composition, boron nitride &ldquo;shell&rdquo; coated ceramic structure, and process of manufacturing

A high emissivity coating composition for coating the interior of a furnace to direct thermal energy toward a load in the furnace wherein the furnace operates above 1100.degree. C. thereby increasing the thermal efficiency of the furnace. The high emissivity coating composition includes a high emissivity agent and a binder agent. The preferred high emissivity agent is cerium oxide which defines a high emissivity factor from approximately 1000.degree. C. to above 2000.degree. C. The binder suspension agent is formulated to define the consistency and drying characteristics of paint such that the coating can be applied in a manner similar to the manner in which paint is applied. Moreover, the binder/suspension agent withstands the final use temperature.

High emissivity coating composition and method of use

A high emissivity coating for coating the interior of a furnace to direct thermal energy toward a load in the furnace wherein the furnace operates above 1100.degree. C. The high emissivity coating includes a high emissivity agent and a binder agent. The preferred high emissivity agent is cerium oxide which defines a high emissivity factor from approximately 1000.degree. C. to above 2000.degree. C. The binder suspension agent is formulated to define the consistency and drying characteristics of paint such that the coating can be applied in a manner similar to the manner in which paint is applied. Moreover, the binder/suspension agent withstands the final use temperature.

High emissivity coating

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 deleterious reactions and emissions when the metal is heated to, or thermally cycled at, temperatures of about 600-900 degrees C. The preferred binder portion of the composition, which in itself provides reasonable protection when dry, consists essentially of an aqueous silica containing solution containing an aqueous alkali, together with oxides selected from the transition metals cobalt, chromium, iron, manganese, nickel, titanium, zinc and zirconium. 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, such as high expansion additives. The coating is useful for other metal and ceramic substrates to prevent or reduce deleterious damage to or emission from the surface at high temperatures.

Paintable compositions for protecting metal and ceramic substrates

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 2000 degrees F., with the resultant deposit being highly adherent and water insoluble after short drying times. This coating has a liquid phase formed from at least water, a pre-reacted lithium silicate, and a pre-reacted potassium silicate. It can also contain a sodium silicate. This coating can be expressed as being about 69 to about 79 wt. % water and about 21 to about 31 wt. % a mixture of R.sub.2 O and SiO.sub.2. The R.sub.2 O is selected from either a mixture of Li.sub.2 O and K.sub.2 O or from a mixture of Li.sub.2 O, K.sub.2 O and Na.sub.2 O. The R.sub.2 O and SiO.sub.2 typically have a molar ratio of about 0.24 to about 0.29, and the K.sub.2 O is about 35 to 85% of the total molar amount of the R.sub.2 O. When Na.sub.2 O is present, it is up to about 10% of the total molar amount of the R.sub.2 O. 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.

Water-insoluble high temperature ink

Alloys such as U-6Nb are prepared by forming a stacked sandwich array of uraniun sheets and niobium powder disposed in layers between the sheets, heating the array in a vacuum induction melting furnace to a temperature such as to melt the uranium, holding the resulting mixture at a temperature above the melting point of uranium until the niobium dissolves in the uranium, and casting the uranium-niobium solution. Compositional uniformity in the alloy product is enabled by use of the sandwich structure of uranium sheets and niobium powder.

Process for alloying uranium and niobium

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.

Growing community of inventors

Knoxville, TN, United States of America

Lloyd R Chapman