Non-carbon anodes for aluminium electrowinning and other oxidation resistant components with slurry-applied coatings

Abstract

A method of manufacturing a component, in particular an aluminium electrowinning anode, for use at elevated temperature in an oxidising and/or corrosive environment comprises: applying onto a metal-based substrate layers of a particle mixture containing iron oxide particles and particles of a reactant-oxide selected from titanium, yttrium, ytterbium and tantalum oxides; and heat treating the applied layers to consolidate by reactive sintering of the iron oxide particles and the reactant-oxide particles to turn the applied layer into a protective coating made of a substantially continuous reacted oxide matrix of one or more multiple oxides of iron and the metal from the reactant-oxide. The metal-based substrate comprises at its surface during the heat treatment an integral anchorage-oxide of at least one metal of the substrate. The anchorage-oxide anchors the multiple oxide matrix to the substrate by reacting with the iron oxide and/or the reactant-oxide to form an integral multiple bonding oxide of the metal of the integral anchorage-oxide and iron from the iron oxide and/or the metal of the reactant-oxide. The particle mixture can be applied in a colloidal and/or polymeric slurry.