US4588655A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Ceramic flame spray powder
Assignee: Eutectic Corp
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Filing: 1984-05-07
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Granted: 1986-05-13
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Expires: 2004-05-07
Abstract
Abstract A flame spray ceramic powder is provided consisting essentially of about 10 to 50% alumina and the balance essentially zirconia. Preferably, the zirconia is stabilized. A method is disclosed for flame spraying the coating composition onto a metal substrate.
Inventors
- 👤 Burton A. Kushner
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-29 00:48
CPC Classifications
C; C23; C23C; C23C4/00; C23C4/04; C23C4/10; C23C4/11; Y; Y10; Y10S; Y10S428/00; Y10S428/922; Y10S428/9335; Y10S428/937; Y10T; Y10T428/00; Y10T428/12; Y10T428/12493; Y10T428/12535; Y10T428/12611; Y10T428/12618
Claims Analysis
Total Claims: 28
Claim 1
Independent Claim
114 words
A method of coating a metal substrate with an adherent layer of a ceramic composition which comprises, flame spraying an alloy bond coat on said substrate, and then flame spraying over said bond coat a ceramic composition consisting essentially by weight of about 10 to 50% alumina and the balance essentially zirconia, said composition being in the form of particles selected from the group consisting of spray dried particles, agglomerated resin-bonded particles and fused particles, whereby a bonded ceramic coating is produced characterized by improved resistance to spalling at thicknesses ranging up to about 0.1 inch and higher and further characterized by being stronger and tougher than flame sprayed coatings of stabilized zirconia alone.
Claim 2
Independent Claim
114 words
A method of coating a metal substrate with an adherent layer of a ceramic composition which comprises, flame spraying an alloy bond coat on said substrate, and then flame spraying over said bond coat a ceramic composition consisting essentially by weight of about 10 to 50% alumina and the balance essentially zirconia, said composition being in the form of particles selected from the group consisting of spray dried particles, agglomerated resin-bonded particles and fused particles, whereby a bonded ceramic coating is produced characterized by improved resistance to spalling at thicknesses ranging up to about 0.1 inch and higher and further characterized by being stronger and tougher than flame sprayed coatings of stabilized zirconia alone.
Claim 3
Dependent Claim
22 words
The method of claim 1, wherein the amount of alumina in the ceramic composition ranges from about 20% to 40% by weight.
Claim 4
Independent Claim
111 words
A method of coating a metal substrate with an adherent layer of a ceramic composition which comprises, flame spraying an alloy bond coat on said substrate, and then flame spraying a ceramic composition consisting essentially by weight of about 10% to 50% alumina and the balance essentially stabilized zirconia, said composition being in the form of particles selected from the group consisting of spray dried particles, agglomerated resin-bonded particles and fused particles, whereby a bonded ceramic coating is produced characterized by improved resistance to spalling at thicknesses ranging up to about 0.1 inch and higher and further characterized by being stronger and tougher than flame sprayed coatings of stabilized zirconia alone.
Claim 5
Independent Claim
111 words
A method of coating a metal substrate with an adherent layer of a ceramic composition which comprises, flame spraying an alloy bond coat on said substrate, and then flame spraying a ceramic composition consisting essentially by weight of about 10% to 50% alumina and the balance essentially stabilized zirconia, said composition being in the form of particles selected from the group consisting of spray dried particles, agglomerated resin-bonded particles and fused particles, whereby a bonded ceramic coating is produced characterized by improved resistance to spalling at thicknesses ranging up to about 0.1 inch and higher and further characterized by being stronger and tougher than flame sprayed coatings of stabilized zirconia alone.
Claim 6
Dependent Claim
18 words
The method of claim 3, wherein the alumina ranges from about 20 to 40% of the total composition.
Claim 7
Dependent Claim
16 words
The method of claim 3, wherein the ceramic coating is produced on a ferrous metal substrate.
Claim 8
Independent Claim
154 words
A method of coating a metal substrate with an adherent layer of a ceramic composition which comprises, flame spraying an alloy bond coat on said substrate, and then flame spraying a ceramic composition consisting essentially by weight of about 10 to 50% alumina and the balance essentially zirconia at least partially stabilized by a stabilizing agent ranging up to about 20% by weight of the mixture of said zirconia and said agent, said stabilizing agent being selected from at least one of the group consisting of neodymia, lanthana, yttria, calcia, and magnesia, said composition being in the form of particles selected from the group consisting of spray dried particles, agglomerated resin-bonded particles and fused particles, whereby a bonded ceramic coating is produced characterized by improved resistance to spalling at thicknesses ranging up to about 0.1 inch and higher and further characterized by being stronger and tougher than flame sprayed coatings of stabilized zirconia alone.
Claim 9
Independent Claim
154 words
A method of coating a metal substrate with an adherent layer of a ceramic composition which comprises, flame spraying an alloy bond coat on said substrate, and then flame spraying a ceramic composition consisting essentially by weight of about 10 to 50% alumina and the balance essentially zirconia at least partially stabilized by a stabilizing agent ranging up to about 20% by weight of the mixture of said zirconia and said agent, said stabilizing agent being selected from at least one of the group consisting of neodymia, lanthana, yttria, calcia, and magnesia, said composition being in the form of particles selected from the group consisting of spray dried particles, agglomerated resin-bonded particles and fused particles, whereby a bonded ceramic coating is produced characterized by improved resistance to spalling at thicknesses ranging up to about 0.1 inch and higher and further characterized by being stronger and tougher than flame sprayed coatings of stabilized zirconia alone.
Claim 10
Dependent Claim
20 words
The method of claim 6, wherein the amount of alumina ranges from about 20 to 40% of the total composition.
Claim 11
Dependent Claim
16 words
The method of claim 6, wherein the ceramic coating is produced on a ferrous metal substrate.
Claim 12
Dependent Claim
25 words
The method of claim 6, wherein the stabilizing agent is calcia which combined with zirconia ranges from about 4 to 8% of the zirconia-calcia content.
Claim 13
Dependent Claim
73 words
A flame sprayed ceramic coating bonded to a metal substrate by means of a flame sprayed intermediate alloy bond coat, said flame sprayed ceramic coating consisting essentially by weight of about 10 to 50% alumina and the balance essentially zirconia, said coating characterized by improved resistance to spalling at thicknesses ranging up to 0.1 inch and higher and further characterized by being stronger and tougher than flame sprayed coatings of stabilized zirconia alone.
Claim 14
Dependent Claim
73 words
A flame sprayed ceramic coating bonded to a metal substrate by means of a flame sprayed intermediate alloy bond coat, said flame sprayed ceramic coating consisting essentially by weight of about 10 to 50% alumina and the balance essentially zirconia, said coating characterized by improved resistance to spalling at thicknesses ranging up to 0.1 inch and higher and further characterized by being stronger and tougher than flame sprayed coatings of stabilized zirconia alone.
Claim 15
Dependent Claim
24 words
The flame sprayed ceramic coating of claim 10, wherein the amount of alumina in the coating ranges from about 20 to 40% by weight.
Claim 16
Dependent Claim
17 words
The flame sprayed ceramic coating of claim 10, wherein the metal substrate is a ferrous metal substrate.
Claim 17
Dependent Claim
72 words
A flame sprayed ceramic coating bonded to a metal substrate by means of a flame sprayed intermediate alloy bond coat, said ceramic coating consisting essentially by weight of about 10 to 50% alumina and the balance essentially stabilized zirconia, said coating characterized by improved resistance to spalling at thicknesses ranging up to 0.1 inch and higher and further characterized by being stronger and tougher than flame sprayed coatings of stabilized zirconia alone.
Claim 18
Dependent Claim
72 words
A flame sprayed ceramic coating bonded to a metal substrate by means of a flame sprayed intermediate alloy bond coat, said ceramic coating consisting essentially by weight of about 10 to 50% alumina and the balance essentially stabilized zirconia, said coating characterized by improved resistance to spalling at thicknesses ranging up to 0.1 inch and higher and further characterized by being stronger and tougher than flame sprayed coatings of stabilized zirconia alone.
Claim 19
Dependent Claim
19 words
The flame sprayed ceramic coating of claim 13, wherein the amount of alumina ranges from about 20 to 40%.
Claim 20
Dependent Claim
17 words
The flame sprayed ceramic coating of claim 13, wherein the metal substrate is a ferrous metal substrate.
Claim 21
Dependent Claim
116 words
A flame sprayed ceramic coating bonded to a metal substrate by means of a flame sprayed intermediate alloy bond coat, said ceramic coating consisting essentially by weight of about 10 to 50% alumina and the balance essentially zirconia at least partially stabilized by a stabilizing agent in amounts ranging up to about 20% by weight of the mixture of zirconia and said agent, said stabilizing agent being selected from at least one of the group consisting of neodymia, lanthana, yttria, calcia, and magnesia, said coating characterized by improved resistance to spalling at thicknesses ranging up to 0.1 inch and higher and further characterized by being stronger and tougher than flame sprayed coatings of stabilized zirconia alone.
Claim 22
Dependent Claim
116 words
A flame sprayed ceramic coating bonded to a metal substrate by means of a flame sprayed intermediate alloy bond coat, said ceramic coating consisting essentially by weight of about 10 to 50% alumina and the balance essentially zirconia at least partially stabilized by a stabilizing agent in amounts ranging up to about 20% by weight of the mixture of zirconia and said agent, said stabilizing agent being selected from at least one of the group consisting of neodymia, lanthana, yttria, calcia, and magnesia, said coating characterized by improved resistance to spalling at thicknesses ranging up to 0.1 inch and higher and further characterized by being stronger and tougher than flame sprayed coatings of stabilized zirconia alone.
Claim 23
Dependent Claim
23 words
The flame sprayed ceramic coating of claim 16, wherein the alumina ranges from about 20 to 40% by weight of the total composition.
Claim 24
Dependent Claim
17 words
The flame sprayed ceramic coating of claim 16, wherein the metal substrate is a ferrous metal substrate.
Claim 25
Dependent Claim
87 words
A flame sprayed ceramic coating bonded to a metal substrate by means of a flame sprayed intermediate alloy bond coat, said ceramic coating consisting essentially of about 10 to 50% alumina and the balance essentially zirconia stabilized by calcia in an amount of about 4 to 8% of the combined zirconia and calcia content, said coating characterized by improved resistance to spalling at thicknesses ranging up to 0.1 inch and higher and further characterized by being stronger and tougher than flame sprayed coatings of stabilized zirconia alone.
Claim 26
Dependent Claim
87 words
A flame sprayed ceramic coating bonded to a metal substrate by means of a flame sprayed intermediate alloy bond coat, said ceramic coating consisting essentially of about 10 to 50% alumina and the balance essentially zirconia stabilized by calcia in an amount of about 4 to 8% of the combined zirconia and calcia content, said coating characterized by improved resistance to spalling at thicknesses ranging up to 0.1 inch and higher and further characterized by being stronger and tougher than flame sprayed coatings of stabilized zirconia alone.
Claim 27
Dependent Claim
23 words
The flame sprayed ceramic coating of claim 19, wherein the amount of alumina ranges from about 20 to 40% of the total composition.
Claim 28
Dependent Claim
17 words
The flame sprayed ceramic coating of claim 19, wherein the metal substrate is a ferrous metal substrate.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1989-05-12 | 1989-11-11 | 1990-05-13 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1993-05-12 | 1993-11-11 | 1994-05-13 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1997-05-12 | 1997-11-11 | 1998-05-13 | $7700.00 | Window Closed / Lapsed |