Patent US5086228A successfully refreshed from Google Patents.
Patent US4752535A successfully refreshed from Google Patents.
US4752535A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Aluminium-based article having a protective ceramic coating, and a method of producing it
Assignee: Norsk Hydro ASA
•
Filing: 1986-01-29
•
Granted: 1988-06-21
•
Expires: 2006-01-29
Abstract
Abstract Described are an aluminium-based article having a heat and corrosion protective coating, especially engine parts such as piston crown or cylinder head, and a method of preparing said article. The coating consists of an aluminium-based bonding layer, preferably having a thickness in the range 0.1-0.6 mm, and an outer top layer of stabilized or partially stabilized zirconium dioxide, preferably having a thickness in the range 0.5-2.5 mm, and optionally a cermet layer, comprising zirconium dioxide and an aluminium-based metal component, between the bonding layer and the outer zirconium dioxide top layer. The bonding layer is applied to the substrate by thermal spraying of a rapidly solidified powder, substantially consisting of 60-80% by weight of Al and 40-20% by weight of Si, the particles of the powder having a frozen unstable micro-structure. The cermet layer desirably is a layer consisting of zirconium dioxide and an aluminium-based alloy, the metal content of the cermet layer decreasing substantially uniformly in the direction towards the outer zirconium dioxide top layer. The cermet layer preferably has a thickness in the range 0.2-0.6 mm. Also the cermet and zirconium oxide layers are deposited by thermal spraying.
Inventors
- 👤 Ingard Kvernes
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-07 20:09
CPC Classifications
C; C23; C23C; C23C4/00; C23C4/02; F; F05; F05C; F05C2201/00; F05C2201/02; F05C2201/021; F05C2201/04; F05C2201/0433; F05C2201/0448; Y; Y10; Y10S; Y10S428/00; Y10S428/922; Y10S428/9335; Y10S428/937; Y10T; Y10T428/00; Y10T428/12; Y10T428/12014; Y10T428/12021; Y10T428/12028; Y10T428/12049; Y10T428/12056; Y10T428/12063; Y10T428/12139; Y10T428/12146; Y10T428/12493; Y10T428/12535; Y10T428/12611; Y10T428/12736; Y10T428/12764
Claims Analysis
Total Claims: 9
Claim 1
Independent Claim
69 words
An aluminum-based article having a heat and corrosion protective coating on at least a portion thereof, said coating comprising a bonding layer applied to said article by plasma spraying of a rapidly solidified Al-Si-based powder comprising from about 60% to about 80% by weight of Al and from about 40% to about 20% by weight of Si, and an outer top layer of stabilized or partially stabilized zirconium dioxide.
Claim 2
Dependent Claim
69 words
An aluminum-based article having a heat and corrosion protective coating on at least a portion thereof, said coating comprising a bonding layer applied to said article by plasma spraying of a rapidly solidified Al-Si-based powder comprising from about 60% to about 80% by weight of Al and from about 40% to about 20% by weight of Si, and an outer top layer of stabilized or partially stabilized zirconium dioxide.
Claim 3
Dependent Claim
31 words
The article according to claim 1, wherein a cermet layer comprising zirconium dioxide and an aluminum-based metal component is provided between the bonding layer and the outer zirconium dioxide top layer.
Claim 4
Dependent Claim
67 words
The article according to claim 2, wherein the cermet layer is a layer consisting essentially of zirconium dioxide and an aluminum-based alloy, and wherein the metal ratio of the cermet layer decreases substantially uniformly in the direction towards the outer zirconium dioxide top layer, and zirconium dioxide ratio of the cermet layer increasing from 0 to 100% zirconium dioxide at the transition into the outer top layer.
Claim 5
Independent Claim
87 words
A method of providing an aluminum-based article, with a heat and corrosion protective coating, comprising steps of applying to at least a portion of the surface of said article, a bonding layer by plasma spraying of a rapidly solidified Al-Si-based powder comprising from about 60% to about 80% by weight of Al and from about 40% to about 20% by weight of Si, and providing an outer top layer of stabilized or partially stabilized zirconium dioxide on top of at least a portion of said bonding layer.
Claim 6
Independent Claim
87 words
A method of providing an aluminum-based article, with a heat and corrosion protective coating, comprising steps of applying to at least a portion of the surface of said article, a bonding layer by plasma spraying of a rapidly solidified Al-Si-based powder comprising from about 60% to about 80% by weight of Al and from about 40% to about 20% by weight of Si, and providing an outer top layer of stabilized or partially stabilized zirconium dioxide on top of at least a portion of said bonding layer.
Claim 7
Independent Claim
115 words
A method of providing a piston crown or cylinder head, with a heat and corrosion protective coating, comprising steps of applying to at least a portion of the surface of said piston crown or cylinder head, a bonding layer produced by plasma spraying a rapidly solidified Al-Si-based powder comprising from about 60% to about 80% by weight of Al and from about 40% to about 20% by weight of Si, applying to at least a portion of said bonding layer a cermet layer comprising zirconium dioxide and an aluminum-based metal component, and providing an outer top layer of stabilized or partially stabilized zirconium dioxide on top of at least a portion of said cermet layer.
Claim 8
Independent Claim
115 words
A method of providing a piston crown or cylinder head, with a heat and corrosion protective coating, comprising steps of applying to at least a portion of the surface of said piston crown or cylinder head, a bonding layer produced by plasma spraying a rapidly solidified Al-Si-based powder comprising from about 60% to about 80% by weight of Al and from about 40% to about 20% by weight of Si, applying to at least a portion of said bonding layer a cermet layer comprising zirconium dioxide and an aluminum-based metal component, and providing an outer top layer of stabilized or partially stabilized zirconium dioxide on top of at least a portion of said cermet layer.
Claim 9
Dependent Claim
69 words
The method according to claim 5, wherein said cermet layer is a layer consisting essentially of zirconium dioxide and an aluminum-based alloy, said cermet layer having a substantially uniformly decreasing metallic proportion in the direction towards the outer zirconium dioxide top layer, the zirconium dioxide proportion of the cermet layer increasing from zero at the innermost portion to 100% zirconium dioxide at the transition into the outer top layer.
References Cited (Backward Citations)
US3006782A
Cited
US3091548A
Cited
US3898053A
Cited
US3920412A
Cited
US4248940A
Cited
GB2003935A
Cited
US4180622A
Cited
WO1982001898A1
Cited
JPS58122077A
Cited
US4421799A
Cited
DE3221230A1
Cited
US4588655A
Cited
US4489140A
Cited
JPS5923865A
Cited
GB2130250A
Cited
JPS6024941A
Cited
EP0139396A1
Cited
EP0166097A1
Cited
JPS6155313A
Cited
US4588607A
Cited
US4645716A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1991-06-21 | 1991-12-21 | 1992-06-21 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1995-06-21 | 1995-12-21 | 1996-06-21 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1999-06-21 | 1999-12-21 | 2000-06-21 | $7700.00 | Window Closed / Lapsed |