Cerolymer®150
Ceramic Composite Coating
Why the need for Zirprotekt coatings on refractories;
High-temperature coatings rely, for protection, on the formation of a dense and adherent surface oxide layer that is chemically stable, thickens slowly with time at temperature, and has good adherence to the coating.
Chromia layers are particularly useful in conferring protection against Type-II hot corrosion7 and intermediate-temperature oxidation, say 600–800 °C, but can be converted to CrO3 at higher temperatures. The rate of formation of this gaseous oxide can be significant in both dry and moist air at temperatures ≥950 °C and chromium-forming coatings have limited usage at high temperatures in such environments. Silica layers are capable of providing protection to very high temperatures, for
example, via ceramic layers on carbon-based materials, to ∼1800 °C.8 They also suffer, however, from concerns with chemical stability in moist environments. Alumina layers do not suffer from such concerns and are the favored means of protection under Type-I hot-corrosion and high-temperature oxidation conditions. Most coatings are now designed to form a continuous alumina layer under these conditions and to have sufficient alumina content to provide a healing capability in the event of cracking or spallation of this layer.
Refractory materials are substances or minerals that have high melting points, and they are difficult to fuse except at very high temperatures. They are processed at high temperatures and are intended for high temp applications. According to Committee C-8 if the American Society for Testing and Materials (ASTM) refractoriness has been defined as, “the capability of maintaining the desired degree of chemical and physical identity at high temperatures and in the environment and conditions of use.”
A refractory coating on the core or mold should have the following characteristics:
- Sufficient refractory properties to cope with the metal being poured
- Good adhesion to the substrate to prevent spalling
- Be permeable to minimize air entrapment
- Be fast in drying
- No tendency to blistering, cracking or scaling on drying
- Good suspension and remixing properties
- Minimize core strength degradation
- Provide adequate protection against metal penetration
- Good stability in storage
- Good covering power
- Good application properties by the method chosen
- Leveling well and minimizing runs and teardrops
- Refractory filler
- Liquid carrier
- Suspension agents (Rheology control system)
- Binder agent
The melting temperature of refractory materials is an important characteristic, showing the maximum temperature of use. It represents fundamental points in phase diagrams used in high temperature chemistry, metallurgy, ceramics, etc.
Using refractory coatings have many benefits, including:
- Reduce or eliminate metal penetration
- Reduce or prevent “burn-on”
- Prevent erosion of sand by molten metal
- Smoother surface finish
- Improve overall casting quality
- Reduced scrap
- Lower cleaning costs
- Physical Characteristics
Colour Light Brown Density ~3.25 gm/cc Cold crushing strength ~340 kg/cm2 Thermal expansion RT-1800°C < 1.0% Shrinkage at 1800°C < 0.25% Thermal Shock Capability Excellent Max. Working Temperature 1800°C - Chemical Characteristics
ZrO2 ~65% (min) SiO2 ~31% Al2O3 ~1.00% Important Note:Please note that the above results are from test samples and should be used only for guidance. This chart is intended to illustrate typical properties of advanced ceramic materials available from M/s Q Gen–next Sustainable Technology Pvt. Ltd. The buyer should recognize that exact properties may vary according to product configuration and may sometimes be tailored to meet specific requirements. The information set forth herein is offered for comparison only, and is not to be construed as absolute engineering data or constituting a warranty or representation for from M/s Q Gen–next Sustainable Technology Pvt. Ltd. assume legal responsibility.
Zirprotekt™-Metal is a Zirconia-based high-performance coating, suitable for applications on metal surfaces, for temperatures upto 1500oC.
- It can be used for a variety of metals, except Aluminium.
- Applications: VALUE TO OUR CUSTOMERS
- Protective coating of metal chimneys, ducts, valves, gates
- Base Plates for Kilns for protecting them against corrosive gases at high temperatures.
- The base substrate can be of Mild Steel / Stainless Steel. The application can be by spraying or trowelling.
- The main purpose is to protect them for damages due to hot corrosive gases, particularly Flue Gases.
- The insulating characteristics of Zirprotekt™-Metal also lower the heat conducted to the base substrate.
- Physical Characteristics
Colour Light Brown Density ~ 2.90 gm/cc Cold crushing strength ~ 297 kg/cm2 Shrinkage at 1200°C < 0.16% Thermal Shock Capability Excellent Max. Working Temperature 1500°C - Chemical Characteristics
ZrO2 ~63% (min) SiO2 ~28% Al2O3 ~1.00% Important Note: Please note that the above results are from test samples and should be used only for guidance. This chart is intended to illustrate typical properties of advanced ceramic materials available from M/s Q Gen–next Sustainable Technology Pvt. Ltd. The buyer should recognize that exact properties may vary according to product configuration and may sometimes be tailored to meet specific requirements. The information set forth herein is offered for comparison only, and is not to be construed as absolute engineering data or constituting a warranty or representation for from M/s Q Gen–next Sustainable Technology Pvt. Ltd. assume legal responsibility.