Zirconium oxide powder containing cerium oxide and yttrium oxide

Claim 2

A flame spray material characterized by ability to produce coatings having low thermal conductivity, comprising a homogeneous ceramic composition consisting of: zirconium oxide optionally containing up to about 10 percent of hafnium oxide based on the total weight of the zirconium oxide and hafnium oxide; cerium oxide; and yttrium oxide; the cerium oxide being present in an amount between about. 23 and 29 percent based on the total weight of the zirconium oxide, hafnium oxide and cerium oxide; and the yttrium oxide being present in an amount between about 1 and 4 percent based on the total weight of the zirconium oxide, hafnium oxide, cerium oxide and yttrium oxide.

Claim 3

Flame spray material according to Claim 1 in which the homogeneous ceramic composition is in the form of powder having a size between about -100 mesh and +5 microns.

Claim 4

Flame spray material according to Claim 2 in which the powder is in the form of composite particles each of which comprises a plurality of subparticles of zirconium oxide , cerium oxide and yttrium oxide, the subparticles having a size less than about 25 microns.

Claim 5

Flame spray powder according to Claim 3 in which the subparticles have a size less than about 10 microns.

Claim 6

Flame spray material according to Claim 3 in which the subparticles are bonded with organic binder in an amount between about 0.2 and 10 percent by weight of the composition.

Claim 7

Flame spray material according to Claim 3 in which the composite particles are sintered.

Claim 8

Flame spray material according to Claim 2 in which the powder is in the form of fused particles.

Claim 9

A flame spray powder having particles of size between about -200 mesh and +25 microns comprising: subparticles of unstabilized zirconium oxide containing up to about 10 percent by weight of hafnium oxide based on the total weight of the zirconium oxide and hafnium oxide; subparticles of cerium oxide; and subparticles of yttrium oxide; organic binder in an amount between about 0.2 percent and 10 percent by weight of the ceramic composition; the subparticles having a size less than about 10 microns ; the cerium oxide being present in an amount of about 26 percent by weight of the total of the zirconium oxide, hafnium oxide and cerium oxide; and the yttrium oxide being present in an amount between about 2 and 3 percent by weight of the total of the zirconium oxide, hafnium oxide, cerium oxide and yttrium oxide.

Claim 10

A flame spray powder having particles of size between about -200 mesh and +25 microns comprising: subparticles of unstabilized zirconium oxide containing up to about 10 percent by weight of hafnium oxide based on the total weight of the zirconium oxide and hafnium oxide; subparticles of cerium oxide; and subparticles of yttrium oxide; organic binder in an amount between about 0.2 percent and 10 percent by weight of the ceramic composition; the subparticles having a size less than about 10 microns ; the cerium oxide being present in an amount of about 26 percent by weight of the total of the zirconium oxide, hafnium oxide and cerium oxide; and the yttrium oxide being present in an amount between about 2 and 3 percent by weight of the total of the zirconium oxide, hafnium oxide, cerium oxide and yttrium oxide.

Claim 11

A process for producing a ceramic coating having low thermal conductivity comprising flame spraying a homogenous flame spray material comprising: zirconium oxide optionally containing up to about 10 percent- of hafnium oxide based on the total weight of the zirconium- oxide and hafnium oxide; cerium oxide; and yttrium oxide; the cerium oxide being present in an amount between about- 23 and 29 percent based on the total weight of the zirconium oxide, hafnium oxide and cerium oxide; and the yttrium oxide being present in an amount between about 1 and 4 percent based on the total weight of the zirconium oxide, hafnium oxide, yttrium oxide and cerium oxide.

Claim 12

A process for producing a ceramic coating having low thermal conductivity comprising flame spraying a homogenous flame spray material comprising: zirconium oxide optionally containing up to about 10 percent- of hafnium oxide based on the total weight of the zirconium- oxide and hafnium oxide; cerium oxide; and yttrium oxide; the cerium oxide being present in an amount between about- 23 and 29 percent based on the total weight of the zirconium oxide, hafnium oxide and cerium oxide; and the yttrium oxide being present in an amount between about 1 and 4 percent based on the total weight of the zirconium oxide, hafnium oxide, yttrium oxide and cerium oxide.

Claim 13

Process according to Claim 9 in which the powder is in the form of composite particles each of which comprises a plurality of subparticles each of zirconium oxide, yttrium oxide and cerium oxide, the subparticles having a size less than about 10 microns.