EP1924536A1 - Couches et corps moules ceramiques stables a haute temperature - Google Patents

Couches et corps moules ceramiques stables a haute temperature

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Publication number
EP1924536A1
EP1924536A1 EP06777010A EP06777010A EP1924536A1 EP 1924536 A1 EP1924536 A1 EP 1924536A1 EP 06777010 A EP06777010 A EP 06777010A EP 06777010 A EP06777010 A EP 06777010A EP 1924536 A1 EP1924536 A1 EP 1924536A1
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EP
European Patent Office
Prior art keywords
reaction product
compound
particles
composition according
component
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP06777010A
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German (de)
English (en)
Inventor
Martin Jost
Ralph Nonninger
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Itn Nanovation AG
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Itn Nanovation AG
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Filing date
Publication date
Application filed by Itn Nanovation AG filed Critical Itn Nanovation AG
Publication of EP1924536A1 publication Critical patent/EP1924536A1/fr
Withdrawn legal-status Critical Current

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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
    • C04B35/111—Fine ceramics
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    • C04B2235/3217—Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
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    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3231—Refractory metal oxides, their mixed metal oxides, or oxide-forming salts thereof
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    • C04B2235/3231—Refractory metal oxides, their mixed metal oxides, or oxide-forming salts thereof
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    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
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    • C04B2235/5418—Particle size related information expressed by the size of the particles or aggregates thereof
    • C04B2235/5454—Particle size related information expressed by the size of the particles or aggregates thereof nanometer sized, i.e. below 100 nm
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    • C04B2235/78—Grain sizes and shapes, product microstructures, e.g. acicular grains, equiaxed grains, platelet-structures
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Definitions

  • the present invention relates to high temperature stable ceramic layers, coatings and moldings and their preparation, their uses and in particular compositions for their preparation.
  • inorganic nanoparticles are suitable as inorganic binder phase in the production of ceramics.
  • WO that nanoparticles are due to their high surface energies able to set at temperatures above 300 0 C a diffusion process in motion, which coarser particles can connect to the atomic level with each other.
  • the nanoparticles used dissolve and lose their previous form. It is also possible to describe this process in such a way that the nanoparticles lie at contact points between the matrix grains and lead to a "sticking together" of the matrix grains, which usually results in porous ceramic layers or porous ceramic shaped bodies.
  • the nanoparticles forming the binding phase constitute the weak point in the structure of the layers and moldings bound with nanoparticles.
  • the abovementioned binding phase is eliminated, which drastically and irreversibly reduces the mechanical stability of the ceramic.
  • the object of the present invention is now to provide a ceramic with improved properties, in particular at high temperatures proves to be stable against chemical attack.
  • the desired ceramic should combine good high temperature properties with the positive properties of the above-mentioned nanoparticle-bound ceramics at lower temperatures.
  • the ceramic itself should also be provided a method for their preparation.
  • a composition of the invention is for the production of high temperature stable ceramic layers, coatings and
  • Shaped body provided and comprises particles of an inorganic
  • Component A and particles of an inorganic component B may together form a eutectic mixture and react at
  • the ceramic layers, coatings and moldings may in some preferred embodiments be silicate ceramics or island silicates such as garnets, in particular Y 3 Al 5 O 12 (YAL) and YaFe 5 O 2 (YAG).
  • YAL Y 3 Al 5 O 12
  • YAG YaFe 5 O 2
  • Oxide ceramics ie ceramics of oxides or oxide compounds with preferably low or no silica content.
  • high temperature stable means in the present case a resistance of the ceramic layers, coatings and moldings against chemical attack (acidic or basic) at high temperatures up to at least 900 0 C, preferably up to 1100 0 C, in particular up to 1400 0 C. Es It is believed that this high resistance is at least partially explained by the formation of a high temperature stable phase (the ternary compound) during sintering.
  • At least two components that are immiscible in the solid state are in such a relationship to one another that they as a whole become liquid or solid at a certain temperature. As a rule, this temperature is below the melting temperatures of the individual components.
  • a composition according to the invention preferably also has nanoscale particles of an inorganic component C, in particular with an average particle size of ⁇ 100 nm.
  • the mean particle size of the nanoscale particles is in particular between 1 nm and 100 nm, particularly preferably between 5 nm and 50 nm, in particular between 5 nm and 25 nm.
  • the nanoscale particles act as inorganic binder (as described in WO 03/93195 Applicant) and strengthen the resulting ceramic layer at temperatures below 1000 0 C.
  • the particles of the inorganic component A used and particles of the inorganic component B form the abovementioned high-temperature-stable phase.
  • this formation is also assisted by the presence of the nanoparticles.
  • the particles of component A and / or of component B are at least partially nanoscale. Like the particles of component C, they also preferably have an average particle size between 1 nm and 100 nm. Within this range, particles with sizes between 5 nm and 50 nm, in particular between 5 nm and 25 nm, are more preferred. Such an embodiment also makes possible the described consolidation of the ceramic layer formed during sintering at lower temperatures, if appropriate also in the absence of particles of component C.
  • Component A preferably has at least one metal compound with in particular divalent metal ion, wherein the metal compound preferably from the group with oxidic Cu, Fe, Co, Zn, Mn, Ce, Sn, Cd, In, Ta , Nb, V, Mo, Y, Ni and W compounds.
  • the metal compound preferably from the group with oxidic Cu, Fe, Co, Zn, Mn, Ce, Sn, Cd, In, Ta , Nb, V, Mo, Y, Ni and W compounds.
  • Cu, Fe, Co and Zn oxides are particularly preferred.
  • Mixed oxides such as indium tin oxide (ITO) and antimony tin oxide (ATO) or precursors to the compounds mentioned can also be used.
  • ITO indium tin oxide
  • ATO antimony tin oxide
  • Component B preferably has at least one in particular oxidic metal and / or semimetal compound.
  • Metal compounds with trivalent or tetravalent metal ion in particular from the group with Al, Fe, V, Cr, Si, Ti and Zr oxides, are particularly suitable. Among the compounds mentioned, preference is furthermore given to Al 2 O 3 , ZrO 2 and TiO 2 , among which Al 2 O 3 is particularly preferred.
  • Component C preferably comprises at least one member of the group with chalcogen-containing compounds, carbides and nitrides.
  • component C is oxidic in nature.
  • component C is in particular at least one member selected from alumina, boehmite, zirconia, yttria-stabilized zirconia, chromia, ceria, iron oxide, silica, tin dioxide and more preferably titanium dioxide.
  • compositions whose components react at sintering temperatures to an aluminate and / or to a Chromeisenspinell (Fe (Cr 1 Fe) 2 O 4 ).
  • titanates may also be preferred.
  • aluminates especially copper aluminate.
  • component B is present in excess.
  • the particles of the component A react substantially completely, whereas particles of the component B due to the excess can also be present in substantial amounts in the reaction product.
  • Component A is contained in the composition, based on the total weight of the solid constituents of the composition, preferably in an amount between 1% by weight and 40% by weight, in particular between 5% by weight and 15% by weight.
  • Component B is present in the composition, based on the total weight of the solid constituents of the composition, preferably in an amount between 50% by weight and 90% by weight, in particular between 70% by weight and 90% by weight.
  • Component C is contained in the composition, based on the total weight of the solid constituents of the composition, preferably in an amount between 1% by weight and 40% by weight, in particular between 5% by weight and 15% by weight.
  • compositions have at least one preferably polar suspending agent. This is preferably water.
  • the amount of the suspending agent contained in a composition of the invention is generally not critical and may be varied depending on the use of the composition.
  • the composition is in the form of a low-viscosity, in particular spreadable, suspension.
  • the composition is pasty.
  • compositions according to the invention frequently also have further, preferably coarser (with sizes up to the millimeter range or even greater), inorganic particles and / or fibers, in particular as fillers.
  • compositions according to the invention are essentially free of alkali metal and / or alkaline earth metal compounds.
  • the invention further comprises a sintered ceramic reaction product, which in particular can be produced from a composition according to the invention. It comprises at least one inorganic compound formed by sintering during a chemical reaction and at least one further inorganic compound.
  • the at least one compound formed during sintering is in particular a compound of the spinel type, preferably an aluminate and / or a chromium iron spinel. Even titanates may be preferred, but copper aluminate is to be emphasized as being particularly preferred. In further embodiments, however, the compound formed during sintering may also be a silicate.
  • the at least one further inorganic compound preferably comprises at least one, in particular oxidic, metal or semimetal compound. Particularly preferred are metal compounds with tri- or tetravalent metal ion, in particular at least one member from the group with Al, Fe, V, Cr, Si, Ti and Zr oxides.
  • the at least one further inorganic compound particularly preferably comprises at least one member from the group with Al 2 O 3 , ZrO 2 and TiO 2 , of which Al 2 O 3 is again particularly preferred.
  • a reaction product according to the invention in preferred embodiments comprises at least one finely divided compound. This preferably has an average particle size ⁇ 1 ⁇ m, in particular between 50 nm and 200 nm.
  • the at least one nanoscale compound is in particular at least one chalcogen-containing compound, a carbide and / or a nitride. So far not already contained as the at least one further inorganic compound in the reaction product, the at least one nanoscale compound comprises at least one member from the group with alumina, boehmite, zirconia, yttrium stabilized zirconia, chromium oxide, cerium oxide, iron oxide, SiO 2 , tin dioxide and particularly preferably titanium dioxide.
  • a reaction product according to the invention preferably has a heterogeneous structure of different particles which are firmly bonded together.
  • the further inorganic compound in the reaction product is preferably in the form of elongated, relatively large particles, preferably with a mean length ⁇ 100 .mu.m, in particular ⁇ 50 .mu.m.
  • the at least one compound formed during sintering is present in the reaction product, in particular in the form of particles having mean particle sizes ⁇ 10 ⁇ m, in particular ⁇ 5 ⁇ m, which connect the elongated particles to one another.
  • particles of the at least one nanoscale compound are also incorporated in the cavities between the larger particles.
  • the presence of the elongate particles may be due to the fact that crystal particles of a composition according to the invention are preferably grown in one direction during sintering. This is presumably attributable to the formation of a local eutectic at the grain boundaries of the crystals, so that a melt phase is formed, which is responsible for the crystals growing in a preferential direction. It is believed that optionally the presence of a nanoscale compound results in a further reduction of the temperature required to form the melt phase of the forming sintered ceramic.
  • Preferred reaction products according to the invention preferably have a composition in which the abovementioned constituents are present in the following proportions:
  • the at least one further inorganic compound - 5 wt .-% to 25 wt .-%, in particular 5 wt .-% to 15 wt .-%, of the at least one compound formed during sintering.
  • the reaction product consists of 70 wt .-% to 90 wt .-% alumina, 5 wt .-% to 15 wt .-% copper aluminate and 5 wt .-% to 15 wt .-% titanium dioxide ,
  • the reaction product consists of 70% by weight to 90% by weight of aluminum oxide, 5% by weight to 15% by weight of iron aluminate and 5% by weight to 15% by weight. titanium dioxide.
  • Reaction products of the present invention are preferably substantially free of alkali and / or alkaline earth ions.
  • a reaction product according to the invention can be present both in the form of a high-temperature-stable shaped body and in the form of a high-temperature-stable layer or coating. It is characterized in particular by an extremely high strength and hardness. Thus, in preferred embodiments, it has a bending strength in the range between 200 MPa to 300 MPa, in particular of about 250 MPa (determined according to DIN ISO 60672). For reaction products which are preferred according to the invention, Vickers hardnesses were determined according to DIN ISO 6507, which are in particular in the range between 12-18 GPa. Also, the uses of a composition of the invention for the production of inorganic moldings, layers and / or coatings and a reaction product according to the invention is the subject of the present invention.
  • compositions of the invention can be further processed by Schlickerguß, film casting, extrusion, Schlickerdruckguß and cold and hot isostatic pressing to moldings, layers and / or coatings.
  • the coating of objects such as heat exchange tubes in power plants should be emphasized.
  • a coated composition according to the invention forms a protective layer which is able to withstand chemical attack, especially at high temperatures.
  • highly aggressive slags such as those produced in combustion processes in power stations and incinerators, do not attack a ceramic layer or coating according to the invention, even at 900 ° C.
  • Another interesting field of application of ceramic reaction products according to the invention is in the field of ceramic filters, the reaction product being suitable both as a ceramic carrier material and for coating a ceramic carrier.
  • the production of monolithic, ceramic shaped bodies from a composition according to the invention also offers clear advantages over the prior art, since it is possible to achieve high component strength even at low temperatures. In other words, it is possible to realize ceramic moldings with high strengths at comparatively low sintering temperatures.
  • the invention also encompasses a method for producing a high-temperature-stable ceramic coating on an article as well as any article which is provided with a reaction product according to the invention, in particular with a coating according to the invention.
  • the method of the invention comprises applying a composition of the invention to an article, optionally removing solvent contained in the composition, and sintering the applied composition.
  • the sintering of the composition is preferably carried out at a temperature> 900 0 C, in particular> 1000 ° C, made.
  • the composition is preferably sintered for a period of at least 2 hours, in particular between 2 and 24 hours. After cooling, a high-temperature-stable, ceramic coating is obtained.
  • Fig.1 Rasterelektronische recording of the ceramic structure produced according to Example 1.
  • Fig. 2 H-SEM image (high-resolution scanning electron image of a ground sample) of the ceramic structure produced according to Example 1.
  • Fig. 3 EDX image of the large bright areas from Fig. 2.
  • Fig. 4 Protective layer provided with power plant slag.
  • an aqueous solution adjusted to pH 2 with HNO 3 is mixed with submicron (average particle size between 100 nm and 1 ⁇ m) ⁇ -Al 2 O 3 (89.5% by weight) and for one hour homogenized.
  • nanoscale TiO 2 rutile, 6.5% by weight
  • micron CuO 4% by weight
  • the cast slip thus obtained can be processed well and is poured into a plaster mold and dried overnight at room temperature.
  • the green body is fired at 1100 0 C for two hours.
  • the sintering leads to brown colored moldings with a largely dense structure and with very good mechanical strength and hardness.
  • the sample which is characterized by excellent strength and high-temperature properties, consists of approx. 87% aluminum oxide, or more precisely corundum ( ⁇ -Al 2 O 3 ), of approx. 7% copper aluminate (CuAl 2 O 4 ) and about 6% titanium dioxide, more precisely rutile (TiO 2 ).
  • Fig. 1 and 2 show scanning electron micrographs of the ceramic structure produced. Good to see are elongated, star-shaped crystals, which are alumina crystals. It will assumes that, in addition to the already mentioned high-temperature stable phase, the barium-shaped aluminum crystals also contribute to the extremely high strength of the ceramic reaction product according to the invention.
  • the formation of the barium-shaped aluminum crystals can be attributed to the fact that the alumina grains in the starting composition are preferably grown in one direction during sintering.
  • the copper oxide added in excess in the starting composition attaches to the grain boundaries of the alumina grains.
  • temperatures above 900 0 C, in particular above 1000 0 C forms at the grain boundaries of a local eutectic, ie a melt phase, which is responsible for the fact that the alumina grains grow in a preferred direction.
  • the eutectic which allows the formation of a melt phase, forms at about 90% alumina and 10% copper oxide.
  • the presence of the nanocrystalline titanium dioxide further enhances this effect.
  • TiO 2 particles and copper aluminate particles can also be seen in the figures (see in particular markings in the high-resolution scanning electron micrograph of a ground sample (HREM) in FIG. 2).
  • Fig. 2 shows that in addition to the aluminum oxide crystals (dark in the picture), titanium dioxide (small bright areas) and copper aluminate, either as CuAl 2 O 4 or as CuAIO 2 , (large bright areas) are present.
  • the copper aluminate was detected by element mapping and EDX spectra ( Figure 3) of the large bright areas in the HREM image. Almost exclusively oxygen, copper and aluminum and virtually no titanium were found here. An element mapping with EDX scan of the dark areas yielded only oxygen and Aluminum, while the small light grains could be assigned titanium and oxygen.
  • 112 g of an aqueous mixture (solids content 75% by weight, water 25% by weight) of a submicron aluminum oxide (70% by weight) with nanoscale titanium dioxide (5% by weight) are stirred for one hour in a high-performance mixer Homogenised with dissolver disc and ZrC> 2 grinding beads.
  • To this mixture are added 3.2 g of Cr 2 O 3 and -1.4 g of Y-Fe 2 O 3 and stirred for a further hour at high speed. This gives a relatively thin slurry, which is also poured onto plaster and dried overnight. After sintering at 1100 ° C. for 4 hours, a gray shaped body is formed whose analysis gives a mixture of aluminum oxide, chrome iron spinel and titanium dioxide (rutile).
  • the cast slip thus obtained can be processed well and is poured into a plaster mold and dried overnight at room temperature.
  • the green body is fired at 1100 0 C for two hours.
  • the sintering leads to brown colored moldings with a largely dense structure and with very good mechanical strength and hardness.
  • Example 2 The casting slip obtained in Example 1 was applied in a layer on a metallic heat exchange tube and sintered after drying overnight at a temperature of 1100 0 C over a period of 2 hours.
  • the composition formed a protective layer on the heat exchange tube.
  • the protective layer was brought into contact with slag from German coal-fired power plants as a test and heated to 900 0 C over a period of 2 hours. However, no reaction was observed between slag and protective layer (no adhesions or the like).
  • Fig. 4 shows such a protective layer provided with power plant slag.
  • a preferred composition for producing a ceramic shaped body is composed as follows:
  • the granules were filled in a screw extruder (company ECT) and extruded by means of appropriate mouthpieces to tubes, strips, U or L profiles.
  • the extruded parts were cut to the required length (between 10 cm and 100 cm) and air-dried overnight.
  • the sintering of the dried green bodies takes place at 1200 ° C. with a holding time of two hours.

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Abstract

L'invention concerne des couches, des revêtements et des corps moulés céramiques stables à haute température, leur production, leurs utilisations ainsi que, notamment, des compositions pour leur production. Une composition selon l'invention comprend des particules d'un constituant inorganique A et des particules d'un constituant inorganique B qui peuvent former ensemble un système eutectique et qui réagissent au moins partiellement l'un avec l'autre à la température de frittage, au moins un composé chimique ternaire, notamment de type spinelle, étant formé.
EP06777010A 2005-08-22 2006-08-22 Couches et corps moules ceramiques stables a haute temperature Withdrawn EP1924536A1 (fr)

Applications Claiming Priority (2)

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DE102005040582A DE102005040582A1 (de) 2005-08-22 2005-08-22 Hochtemperaturstabile keramische Schichten und Formkörper
PCT/EP2006/008246 WO2007022957A1 (fr) 2005-08-22 2006-08-22 Couches et corps moules ceramiques stables a haute temperature

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EP (1) EP1924536A1 (fr)
JP (1) JP2009504564A (fr)
KR (1) KR20080046165A (fr)
CN (1) CN101309880A (fr)
BR (1) BRPI0614878A2 (fr)
CA (1) CA2619728A1 (fr)
DE (1) DE102005040582A1 (fr)
WO (1) WO2007022957A1 (fr)

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US8062775B2 (en) * 2008-12-16 2011-11-22 General Electric Company Wetting resistant materials and articles made therewith
US8449993B2 (en) * 2009-08-31 2013-05-28 General Electric Company Wetting resistant materials and articles made therewith
DE102010004960A1 (de) * 2010-01-20 2011-07-21 J. Eberspächer GmbH & Co. KG, 73730 Rohrkörper und Abgasanlage
CN106810242A (zh) * 2015-11-30 2017-06-09 比亚迪股份有限公司 锆基复合陶瓷材料（杏色）及其制备方法与外壳或装饰品
CN106601356B (zh) * 2016-12-21 2017-12-29 川叶电子科技（上海）股份有限公司 一种耐高温电线及相应的复合前驱体陶瓷带的制备方法
JP6586250B1 (ja) * 2018-06-01 2019-10-02 積水化学工業株式会社 硬質塩化ビニル系樹脂管

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CA2619728A1 (fr) 2007-03-01
WO2007022957A1 (fr) 2007-03-01
KR20080046165A (ko) 2008-05-26
CN101309880A (zh) 2008-11-19
US20090253570A1 (en) 2009-10-08
JP2009504564A (ja) 2009-02-05
DE102005040582A1 (de) 2007-03-01
BRPI0614878A2 (pt) 2011-04-19

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