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We have added more information about our products in the General Information Section. If you are new to coatings there is a tutorial and a page explaining the Miracle of BN Coatings. You may want to start with the Paint Selection Guide.
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Dry Film Lubricants has been added to our website.
Dry film lubricant (DFL) coatings of Boron Nitride and Super Enhanced Graphite (SEG) were developed by ZYP Coatings, Inc. in order to provide ready-to-use aerosol formulations that give superior performance in lubrication.
A dry film lubricant is a fine-particle mixture of a lubricating material and binders. With our aerosol-can formulations, after merely spraying onto a surface and drying (which takes only a minute or so), the lubricant is attached to the surface and reduces friction while increasing wear-lifetime -- operating from low-temperature up to very-high temperatures [cryogenic up to 1000 C].
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The Blackbody/High-Emmisvity coatings have a new addition -- TBBC-CE, a water-based Cerium Oxide coating usable mostly from 1100 C to 1600 C.
Each of the primary materials used in our coatings [Aluminum Oxide, Boron Nitride, Titanium Nitride, Yttrium Oxide, and Zirconium Oxide] has been given a webpage-link "What Makes xxxxxx Unique" about the material and a webpage-link with the "Properties and Compatibility Data" for the material.
A "Compatibility Guide" now enables one to see what reacts with what and what doesn't ... when selecting a coating for specific areas-of-interest.
Specific coating-use examples for molten nonferrous metal areas-of-use are given at the General Information webpage -- which can show someone immediately what coating is typically used for their problem area.
A new addition at Substrates is Substrates-Fibrous, which refers to fiber-blanket insulation. Coatings and/or rigidizers for these are discussed.
Coatings considered by Carrier/Vehicle at General Information shows our three coating types -- water-based (the primary ones), solvent-based, and oil-based [where the coating TPC-LL is described].
2008
ZYP Coatings, Inc. introduces its new and colorful 1-gallon pails
for Boron Nitride Hardcoat®, Boron Nitride Lubricoat®
and Boron Nitride Releasecoat®
The new pail highlights ZYP Coatings as “World Leader in Boron Nitride Coatings” and that the paint is formulated with Ultra-High-Purity Boron Nitride.
NEW ZYP COATINGS' TRADEMARK
RELEASECOAT-BLUE® is a recently-registered ZYP Coatings' trademark. This again emphasizes the innovation of permanently-BLUE-colored boron nitride paint which allows immediate visual determination of areas that have been coated. THINK BLUE, THINK ZYP.
From Second Half 2004
COATINGS FOR MOLTEN LEAD APPLICATIONS
ZYP Coatings, Inc. has received reports that boron nitride coatings can be used successfully with molten lead operations. Lead oxide reportedly reacts with boron nitride, albeit at relatively high temperatures [i.e., over 800 C or 1500 F or so]. As a result of this reported interaction, in the past, coatings of zirconia [such as Type ZO, Z-Aerosol, Zircwash] and Sealmet have been utilized for molten lead applications. However, those refractory coatings do not exhibit the very-desirable non-wetting properties that boron nitride coatings produce. The recent field-use information indicates that the BN-Aerosol-Brushable [Boron Nitride Aerosol Brushable] can be successfully used for molten lead with metallic molds and mild-steel pouring ladles [even where lead-dross buildup occurs]. Excellent non-wetting performance occurs. The water-based boron nitride coating, BN-Lubricoat-ZV [for better hardness and abrasion-resistance], is also be a good candidate for these areas.
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From First Quarter 2003
HIGH-PURITY BORON NITRIDE [BN] POWDERS
ZYP Coatings' new, unique, state-of-the-art continuous process allows the production of highly-controlled, high-purity Boron Nitride [BN] powders, which are offered as
•
Grade ZG for general uses
• Grade PS specially designed for electrostatic spray systems for
precision aluminum processing – available from
CASTOOL.
These BN powders have unique properties, including high refractoriness, high thermal conductivity, good dielectric properties, lubriciousness, and excellent chemical resistance and resistance to molten non-ferrous metals [Al, Mg, Zn]. Utility of these powders is broad, covering many areas of industrial and R&D, including as a few examples:
• plastics, potting compounds, greases, and other material [“bulk” additions
to provide enhanced thermal conductivity and dielectric strength]
• for electrostatic spray systems [with precision aluminum extrusion etc.]
• as a dry-film lubricant and release agent
• for ceramic applications, such as additives to refractories
ZYP Coatings’ high-purity Boron Nitride powders are further discussed/detailed at
www.bnpowder.com
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From Second Quarter 2003
OXIDATION-RESISTANT AND WEAR-RESISTANT CERAMIC – BORACARBTM
An evolutionary breakthrough that enables GRAPHITE to be engineered as a new high-temperature ceramic material for use in oxidizing environments above 900 C (1650 F) has been developed by ZYP Coatings.
Graphite offers many useful properties – excellent thermal shock resistance, low cost, easy machinability, chemical resistance, good thermal conductivity and more. However, its main limitation is oxidation in air above about 450 C. The ZYP-developed BORACARBtm process is an ultra-high-temperature gas phase treatment that produces a protective “case” conversion layer similar in concept to carburizing or nitriding of steel. With the BORACARBtm treatment, graphite is protected from oxidation in air up to 900 C (1650 F) for THOUSANDS OF HOURS.
In the past, short-term graphite oxidation protection has been provided by ceramic paints, and coatings. However, these have provided limited protection and are easily damaged in use. The BORACARBtm case depth provides long-term protection and is robust in use. The BORACARBtm treatment also provides an extremely WEAR RESISTANT LAYER which is also ELECTRICALLY INSULATING, thereby allowing graphite to be used in new and expanded areas.
BORACARBtm is further detailed at
www.boracarb.com. If justified by the graphite part numbers needed per unit of time, sizes, and variations in the parts, ZYP Coatings will consider providing BORACARBtm in a toll-processing fashion.
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From Fourth Quarter 2003
PUBLISHED ARTICLE OF INTEREST – BN FOR ALUMINUM EXTRUSION
April 2003, Light Metal Age, V. 61 [Nos. 3-4], p. 86,“New Equipment Spotlight” – discusses
Boron Nitride electrostatically-applied powder and Boron Nitride coatings used in aluminum extrusion areas.
NOTE: Contact
Castool for special grade boron nitride powder , electrostatic spray systems, and coatings used in the aluminum extrusion areas.
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From Second Quarter 2002
COATINGS FOR DIAMOND TOOL PRODUCTION PROCESSING
White Silk Boron Nitride aerosol is designed especially as a release agent to prevent diamond matrix or metal bond powder from sticking to graphite molds and plungers/punches at diamond segment production sintering temperatures to above 850 C.
This White Silk Boron Nitride is an economical, cost-effective release agent – available only in case-lots of twelve 13-oz. aerosol spray cans that provides fast drying and ease of use.
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From Third Quarter 2002
ZYP COATINGS-PYROTEK MARKET DEVELOPMENT MANAGER
John Blasen is the joint ZYP-Pyrotek Market Development Manager for ZYP Coatings that are sold through Pyrotek, Inc. in the United States and worldwide
www.pyrotek.info . John has extensive experience with Pyrotek, Inc. John coordinates market and product development/ promotion for ZYP Coatings' specialty coatings sold into the molten and extruded aluminum and magnesium industries that are distributed by Pyrotek, Inc.
Contact John concerning any questions related to ZYP-Pyrotek coating areas. He is based out of the Pyrotek Corporate office.
Cell: 425-238-6347
Office Telephone: 509-926-6212 x277
Office Line Direct: 509-340-2885 (voice mail available)
E-mail:
johbla@pyrotek-inc.com
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From Fourth Quarter 2002
STATE-OF-THE-ART CONTINUOUS PROCESS FOR THE PRODUCTION OF BORON NITRIDE POWDERS
ZYP Coatings, Inc., the world's premier manufacturer of quality Boron Nitride Paints, has successfully developed and brought on-line its new, state-of-the-art continuous process for the production of Boron Nitride powders. Available for select toll-processing or licensing, the unique ZYP Continuous Process allows, for the first time, the feasibility for end users of specific grades of BN powders [such as the cosmetic or refractory industries] to economically produce their Boron Nitride powder requirements.
Traditional batch processing for Boron Nitride powders utilize a "pot" whose size renders the resulting powder very non-uniform. The powder purity, crystallinity (lubriciousness and shine) as well as color (which can vary from white to gray to black to yellow) varies from the center of the "pot" to the edge of the "pot". As the result, powder is normally subgraded for a variety of end users and applications. It is this variation that prevents the batch process from being practical for users of a single grade or limited grades of BN powder - such as for cosmetics.
The ZYP Continuous Process produces extremely uniform product of a single grade once the process parameters are set. Process parameters are adjustable to change grades as required to meet specific needs. The economics and ease of the Continuous Process are very favorable and can be realized even for very low production volumes of about 1500 to 2000 pounds per month.
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From Third Quarter 2001
GALVANIZING STOP-OFF PAINT
MASKOTE ZINC STOP-OFF is a zinc stop-off paint that has long been needed for hot-dip galvanizers and their customers. MASKOTE stops galvanizing in unwanted areas, such as threads, weld areas, and joints. A fast-drying paint that requires no curing, MASKOTE allows both alkaline and acid cleaning after coating! After applying by brushing or dipping, the coating will fast dry and can immediately be placed into service. Then, post-galvanizing, the coating is easily removed with pressurized water rinse and/or by mechanical means.
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From First Quarter 2001
PUBLISHED ARTICLES ON ZYP COATINGS’ PAINTS
March 2001, Aluminium Today, "BORON NITRIDE COATINGS PROVIDE TRUE NONWETTING FOR ALL LIQUID ALUMINIUM TRANSFER COMPONENTS" – presents information is directed towards the use of boron nitride in the casthouse as well as other areas where molten aluminium is processed -- CASTING TABLES; TRANSITION PLATE/RING SEAL; TROUGHS AND LAUNDERS; MOULDS; LADLES/ SKIMMERS; PINS/SPOUTS AND OTHER MOVING SURFACES; ROTARY DEGASSERS.
April/May 2001, Aluminium Times, “MIRACLE OF BORON NITRIDE LUBRICOAT® COATINGS PROVIDES TRUE NONWETTING FOR MOLTEN ALUMINIUM AND MAGNESIUM” – explains the reasons for the use of the statement "Miracle of Boron Nitride Lubricoaẗ" while detailing the use of the coating for CASTING TIPS and FILTER BOXES. Other uses, such as for CASTING TABLES, TRANSITION PLATES, TROUGHS, LAUNDERS, TUNDISHES, FUNNELS, RUNNERS, GATES, BASINS, STAULK TUBES, RISERS, PINS, SPOUTS, PERMANENT MOULDS, and LADLES and SKIMMERS are also discussed. As mentioned in the editorial, the smooth flowing action that provides more efficient transfer of the molten metal cannot be fully described in words: it is part of the "Miracle of Boron Nitride Lubricoat®" that has to be seen to be believed.
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From December 2000
BORON NITRIDE COATINGS FOR GALVANIZING ROLLS
There has been a long-standing problem with the large metal rolls that are used in zinc baths to pull the metal being galvanized under the rollers. Zinc and dross buildup on the rollers eventually shuts down the galvanizing line, often requiring that the metal rolls be sent off for re-machining/re-building. This is a significant problem with production being shut down on the galvanizing lines. Several customers have used our boron nitride coatings on these metal rolls and have achieved multiple "campaign" runs -- thus greatly improving the life of the steel rolls. The rolls were coated, then air dried; then the rolls were wrapped in a heater blanket, starting at around 300 F (150 C), increasing to 550 F (290 C). After this heating, the heated rolls were immersed into the 750 F (400 C) zinc baths for the operation. Boron Nitride Lubricoat-ZV has been used for this area-of-use due to its alkaline pH allowing it to be used on plain or carbon-steel substrates.
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From November 2000
BORON NITRIDE LUBRICOAT® PROVIDES IMPROVED HEAT TRANSFER WITH ITS HIGH THERMAL CONDUCTIVITY
ZYP Coatings' Boron Nitride Lubricoat¨ has high thermal conductivity for a ceramic material, resulting from the thermal conduction of boron nitride being about the same as stainless steel. Because of the fact that Boron Nitride Lubricoat¨, being soft and lubricious, can be coated onto metals and ceramics, this versatile coating can be applied to mating components whenever optimum heat transfer is desired. Also, since Boron Nitride Lubricoat¨ is electrically insulating, the coating can be used in areas where electrical isolation is desired, yet the high thermal conduction is also needed. Additionally, boron nitride is non-reactive to most metals, ceramics, glasses, drosses, etc. and can be applied in areas where reactions with these materials should be prevented. When a coating of boron nitride is applied to dissimilar materials, the heat transfer tends to be equalized - with the boron nitride spreading out the "hot spots" and evening out the heat. Under conditions where the acidic pH of Boron Nitride Lubricoaẗ may present a problem, other candidate boron nitride coatings, such as Boron Nitride Lubricoaẗ-ZV [pH alkaline] or Type BN High Purity Boron Nitride Paint [pH neutral], may be used.
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From March 2000
PUBLISHED ARTICLE ON ZYP COATINGS’ PAINT
December 1999, Aluminium Today, p. 26, "Casters Turn Blue with Boron Nitride Lubricoat" – highlights our blue coatings for molten aluminium areas. Our development of the highly-visible, permanently-blue coatings was noted to help operators monitor the condition of their coatings, improving both operation and maintenance.
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From February 2000
BORON NITRIDE LUBRICOAT¨ COATINGS ARE IDEAL FOR CERAMIC PINS AND SPOUTS
Boron Nitride Lubricoat
BN-Lubricoat-Blue
BN-Lubricoat-ZS
BN-Lubricoat-ZV
are safe, water-based Boron Nitride paints for ceramic pins and spouts used in the transfer of molten aluminum and magnesium. The LUBRICOAT®-ZS and ZV coatings are dilutable to most any level, permitting easy dip-coating of ceramic bodies without degrading performance.
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From January 2000
SMALL SCALE R&D TESTING OF ANY PAINT CAN BE EASILY DONE
There is often a need for testing paintable coatings for possible applications. We generally recommend testing coatings by brushing onto an appropriate substrate, since that is the easiest way to test. A bristle brush or a foam rubber brush will provide a good coating to evaluate. For water-based coatings, when applying onto a porous substrate, it is sometimes beneficial to pre-wet the surface with water before applying the coating: this will allow the substrate to "suck" the liquid first and prevent overdrying the coating ö which can lead to poor coverage as well as a crackled surface in some cases.
Ceramic substrates are very forgiving in general. Our paintable coatings can be applied in most any fashion that is used for house paint (brush, air-spray, or even dipping), and the coatings will usually perform well. However, for metal substrates, more effort is required in order to get good test results. We use aluminum, stainless steel, or carbon steel coupons for testing. It is preferable to clean the coupons with a mild solvent before coating them (this will remove any greases or dirt that may be on the surface, although unseen). Often it is good to test the metal coupons with their normal, somewhat-polished finish as well as with a grit-blasted or sand-papered finish: this will determine the degree of improvement that results from such pre-conditioning. For metals, the rule of thumb is to always apply the thinnest coating that will do the job: or, thin is good; thick is not. The thinner coatings (preferably 0.001 to 0.003 inches) will allow much greater thermal expansion mismatches and will generally give the same performance with protecting the metal during high-temperature usage.
For graphite, it is preferable to roughen the surface with sandpaper or light grit-blasting and then to clean off as much of the residual graphite dust as possible, using acetone, alcohol or other solvent-soaked soft cotton cloth or the like. After drying, then the surface can be coated. Virtually any surface of soft material (ceramic, graphite, etc.) will have surface dust on it, and painting over the dust is similar to painting a freshly sawed piece of wood with sawdust all over it. The paint will stick to the sawdust and not to the wood ö thus will delaminate VERY easily. So...if you clean off any such dust, the coating will adhere to the base substrate, which is what you want for maximum adherence.
For any substrate, it is nice to be able to simulate production air-spraying operations without having to use the pressurized spray guns that are typical for those applications (see our "Useful Links" section for links to DeVilbiss, Binks, and Grayco production air-spray units). We have tried pump sprayers such as used for window-cleaners; we emptied out the residual cleaner and loaded them with our paintable refractory materials. The results are quite spotty, literally, but are adequate for some applications. We have also used house paint sprayers which are suction-fed instead of pressure-fed: the suction-fed sprayers also lead to spotty, gritty coatings...but are adequate for some tests as well as some applications. Some customers have actually used pump sprayers (such as used for applying weed killer to lawns, etc.) for coating parts: of course, the quality of the coatings are poor, but, for some testing, etc., this still leads to adequate performance. For R&D testing, we have successfully used artist-type air brush equipment for very-small-scale work: the main problem with these systems is plugging and clogging of the spray tip. Some of our coatings simply will not feed through them. We have found a small commercial spraying tool (see our "Useful Links" section for "Spra-Tool") that simulates a commercial spray gun and/or our aerosol cans. The advantage is that you can use it with virtually any of our paintable refractory coatings for small-scale testing. It will atomize any water-based or solvent-based coating but does require that they be thinned to milk-like consistency. The system is a plastic container (in which you put the coating) that is connected by a snap-on "head" to a propellant unit: pressing the trigger feeds the propellant which sucks the coating along to atomize it.
When you are testing or applying any of our coatings, please consult our "Painting Instruction Guide" for detailed descriptions/hints on application, etc.
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From December 1999
BORON NITRIDE LUBRICOAT HAS MANY ADVANTAGES IN FILTER BOXES
For ceramic filter boxes, Boron Nitride coatings
BORON NITRIDE LUBRICOAT® [White version]
BORON NITRIDE LUBRICOAT®-BLUE
BORON NITRIDE LUBRICOAT®-BLUE-ZS
extend the life of the filter box by providing a barrier layer that prevents attack from the molten metal and its concentrated impurities. Also, due to its release-agent characteristics, the BORON NITRIDE LUBRICOAT® coatings allows the filter to be easily removed from the box with no sticking!
The BORON NITRIDE LUBRICOAT® coatings can be easily applied as a thin coating (about 0.002-0.004 inch [2-4 mils]) by air-spraying onto the walls of the filter box -- providing
* Much Easier Clean-up: When the filter is removed by merely lifting the filter out,
the box is protected since jerking and prying are not needed. The remaining aluminum/skull can be simply lifted out or brushed off the walls and removed.
* Less-Frequent Coating: Because of the special ceramic binder systems with BORON NITRIDE LUBRICOAT̈ coatings, the Boron Nitride layer is "glued" to the ceramic of the filter bowl, thus lasting for days longer than bone ash or "R-20" powder. Also, because of the non-wetting, Teflon̈-like nature of BORON NITRIDE LUBRICOAT̈ coatings, they are not pulled off the ceramic like other coatings and thus do not have to be recoated after every drop.
Many customers have reported that BORON NITRIDE LUBRICOAT̈-coated filter boxes are quite dramatic in use.
Teflon® Trademark of DuPont.
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From November 1999
YTTRIUM OXIDE FOR TRAYS ETC.
As for most of its areas of use, yttrium oxide is used where other coatings fail. Recently, it has been reported that yttrium oxide coatings provide excellent barrier layers on trays used for sintering titanium components. Titanium, as a very reactive metal, is often sintered or high-temperature bonded or otherwise processed at temperatures of 1100 C (2000 F) to 1400 C (2550 F). At these high temperatures, often with high-vacuum or inert gas (partial pressure) processing, eutectics with metal trays such as molybdenum or tungsten would occur. A thin coating of yttrium oxide prevents any sticking or interaction. Also, for graphite trays and molds used with titanium parts, yttrium oxide acts as a barrier and an anti-stick coating. Yttrium oxide has proved itself for powder metallurgy sintering as well as diffusion bonding/welding of titanium or its alloys in bulk or in areas of application of beads to a substrate. Additionally, for brazing and welding areas with reactive alloys like titanium or others (cobalt-containing alloys; hafnium-containing alloys, beryllium alloys, uranium alloys), yttrium oxide also is the solution.
Our line of yttrium oxide coatings includes high-purity, solvent-based Type YK coating; high-purity, water-based Type Y coating; Y-Aerosol [and its “bulk” paint form Y-Aerosol-Brushable] for easy-to-apply convenience.
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From October 1999
BORON NITRIDE LUBRICOAT̈ PROVIDES MANY ADVANTAGES FOR CASTER TIPS
For ceramic caster tips, BORON NITRIDE LUBRICOAT̈ induces better flow through the caster tip at startup -- thus eliminating blow-outs, reducing sheet thickness variations, and easing sheet feeding through the guide rollers. In addition to easier startups, the BORON NITRIDE LUBRICOAT̈
* assures constant thermal conductivity of the tip for the duration of the cast
* eliminates reactions of the caster tip and the molten aluminum
* prevents the aluminum from developing voids that will cause piping defects in the
sheet during rolling
The BORON NITRIDE LUBRICOAT®, when compared to Fiberfraẍ papers, also exhibits advantages
* BORON NITRIDE LUBRICOAT® stays in place, being bonded to the ceramic
caster tip. Fiberfrax¨ papers, on the other hand, deteriorate as the binder
fails at the molten metal temperatures – with the residue being deposited
onto the sheet, later being rolled into the finished product.
* BORON NITRIDE LUBRICOAT® is easy-to-apply, like house paint.
Fiberfraẍ papers must be cut and bonded into place – difficult and time consuming.
It is easy to apply the BORON NITRIDE LUBRICOAT® to the ceramic caster tips, with the best application resulting with air-spraying around 0.003 inches (3 mils) of the coating onto the inside of the caster tip and also on the last two inches outside the tip. After drying the coating, an excellent finish can be obtained by polishing the surface with a piece of paper that has been folded in half twice. Then, the coated surface can be heated to around 150 C (or around 300 F) after which the process can be repeated to attain a total coating thickness of 0.006 inches (6 mils) before placing into use.
Customers have reported that these boron nitride-coated caster tips perform excellently, lasting for runs as long as 1.5 million pounds.
Fiberfraẍ – Trademark of Unifrax (formerly Carborundum).
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From August 1999
NDB STOP-OFF COATING IS THE "DO-ALL" WATER-BASED COATING FOR HEAT TREATING
ZYP Coatings’
NDB (Nitrogen Diffusion Barrier) Stop-Off Coating was originally developed in 1986 for use with salt bath cyaniding (carbonitriding). The coating was quickly proven also to be very effective for fluidized bed nitriding, which is still a major area for its use. Over the years, NDB Stop-Off has been used when other coatings (such as the solvent-based, copper-containing coatings or the water-washable stop-offs that are used for vacuum and gas carburizing) have problems or just do not work at all. For alloy steel (such as the 8000 series steels), for instance, the water-washable stop-offs often fail to perform or give inconsistent performance, yet NDB Stop-Off works well. For a SAE 1536 carbon-manganese steel part used for carbonitriding, again the NDB has been proven to give superior performance with the natural gas-ammonia-nitrogen atmosphere to provide the necessary control during the heat treating. The NDB Stop-Off has been shown to be effective with heat treating processes on all types of metals up to 2000 F – providing a hard, abrasion-resistant barrier layer. Also, the NDB is easy-to-apply, just like ordinary house paint; and, because it is water-based, it is easy to clean up and causes no environmental and flammability problems like the solvent-based stop-off coatings. After use, the NDB can be removed with a steel brush or other mechanical means.
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From July 1999
BORON NITRIDE HARDCOAT FOR IMPROVING LIFETIME OF CAST IRON STAULK TUBES
Boron Nitride HARDCOAT is a thin, easy-to-use coating that can be applied by brush, dip, swab, or spray application. The Boron Nitride HARDCOAT is effective because it provides a durable non-wetting layer of protection, stopping molten metal penetration and reaction. Thus, for cast iron staulk tubes, burn-through and dissolution of the tubes by molten aluminum and its alloys are prevented. The Boron Nitride HARDCOAT provides superior wear and erosion resistance also, as well as allowing easy removal of any adhering dross or skin. The performance of coated tubes leads to a doubling of their lifetimes, often resulting in substantial cost savings.
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From June 1999
COATINGS FOR REDUCING REACTIONS WITH METAL COMPONENTS
UNDERNEATH CERAMIC INSULATION
Our customers have indicated the solution of problems associated with metal components that were badly corroding from hydrochloric acid vapors penetrating ceramic insulation and attacking the metal. This situation occurs in certain titanium dioxide manufacturing processes as well as incinerators/burners. The attacking vapors can be stopped by coating the metal (i.e., low-carbon steel or others) with BORON NITRIDE HARDCOAT. The temperature of the reactors/furnaces was generally around 1000 C (1832 F), which is above the generally recommended use-temperature for BORON NITRIDE HARDCOAT. The ceramic insulation apparently allows the coating to be used under these conditions, however.
For higher temperatures and other situations, our
SEALMET coating is a candidate coating to provide protection for such metal components.
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From March 1999
COATINGS FOR SEALING POROSITY
FOR CERAMIC STAULK TUBES AND OTHER SURFACES
There are situations where porous ceramics are used in which the open porosity presents a problem. One such area is ceramic staulk tubes. For these tubes, two of our products have been investigated by our customers -- Boron Nitride HARDCOAT and MW-50 Paste. Some customers prefer a thin coating and have used the Boron Nitride HARDCOAT to coat both inside and outside of the staulk tubes. If a thick coating is desired (of 0.010 inches or 0.25 mm or more), the MW-50 is generally used – such as on the outside of staulk tubes.
Another sealing-type of coating is
Coverguard, which seals porosity for graphite to prevent its burning/oxidation and does the same for many ceramic bodies, whenever a relatively thin coating is desired. This coating has been used to seal the surfaces of graphite rotors and stators used for degassing units in molten aluminum – particularly at the metal-air interface where oxidation of the graphite occurs along with erosion/abrasion from the dross. Also, MW-50 can be used in the areas subjected to the greatest attack, since MW-50 allows a thick layer (even up to 0.25 inch) to be built up. In some cases, the Coverguard or MW-50 is also topcoated with Boron Nitride LUBRICOAT¨ to get complete non-wetting by the molten aluminum.
Another coating that has been used for sealing ceramics and graphite is Z-Guard. This abrasion-resistant zirconia coating is not recommended for vacuum use on graphite above 1000 C.
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From January 1999
VERSATILE BORON NITRIDE PASTES
ZYP Coatings, Inc. offers three boron nitride pastes --
WATER-BASED BORON NITRIDE PASTES
Boron Nitride Lubricoat® Paste – acid pH, good adherence, somewhat corrosive to ferrous metals; uses aluminum oxide binder (25% on fired basis)
Boron Nitride Lubricoat® - BNW Paste – neutral pH, moderate adherence, non-corrosive; uses magnesium silicate binder (8% on fired basis)
NONAQUEOUS-BASED BORON NITRIDE PASTE
Paste BNA – alcohol/ethyl acetoacetate carrier, moderate adherance; non-corrosive; uses magnesium silicate binder (5% on fired basis) and glassy carbon binder (5% – burns out in air); ideal for use on calcium silicate boards or other water-reactive substrates.
Unlike paints that require many coats by brushing, rolling, or air-spraying to develop a thick layer, pastes provide rapid buildup of thick layers by brushing, sponging, troweling, spatulating, or hand rubbing/packing into place. Like the ceramic paints, the pastes are simply applied to a surface, allowed to dry thoroughly, and placed into high-temperature usages. These pastes can be used for areas that require sealing, veneering, caulking, stuccoing, grouting, or mortaring onto ceramic, metal, or graphite components that are used in high-temperature operations. As with other boron nitride-based materials, the pastes have excellent high-temperature lubricity, good thermal conductivity, and high electrical resistivity – while being stable with most glasses and fused salts, and being non-wetting with molten aluminum and magnesium and their alloys and drosses. Application can be made onto porous substrates such as fiberboards, insulating bricks and other substrates.
Uses of these pastes include patching, repairing, filling, lining, assembling, potting, encapsulating. All these areas usually would be difficult or impossible to utilize a ceramic paint instead of a thick paste. Surfaces coated with the pastes have included bricks, cores, crucibles (and joints/crevices in crucibles or brick liners), troughs, spouts.
If a spatula is used for application, it is helpful to pre-wet the spatula with the carrier of the pastes (either water or ethyl alcohol) to get the best spreading. Likewise, any surface that is pre-wetted with the carrier of the pastes (either water or ethyl alcohol) will be easier to coat and give better spreading of the pastes.
The Boron Nitride Lubricoat¨ Paste has been used for ceramic-hot-pressing and also for glass-forming operations. The other pastes are also applicable: however, each process generally leads to one paste being preferred. All the pastes are usable to 1100 C in air, 1400 C in vacuum, and 1800 C in inert atmospheres.
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From November 1998
UNUSUAL USES OF COATINGS WITH PERMANENT-MOLD PROCESSING OF IRON AND COPPER
Customer feedback indicates Boron Nitride Lubricoat (water-based or aerosol) is useful for permanent molding of iron or copper parts – in areas of gates, runners, as well as the casting cavity. Boron Nitride paints would not normally be expected to perform in air environments at the processing temperatures used with these metals. However, underneath the molten iron or copper, the Boron Nitride does not oxidize and still provides its excellent non-wetting and release properties. For permanent mold casting of ductile cast iron at 1400 C, for example, coating a copper die leads to excellent release for multiple castings (i.e., 50 shots typical). Also, in permanent mold casting of copper, Boron Nitride Lubricoat (water-based) is an excellent release agent in the mold areas.
These examples have shown that Boron Nitride can often be used in applications above its normally-expected use-temperature in air – since the molten metal is more likely to oxidize than the Boron Nitride. In areas above the melt line or where the Boron Nitride does not perform well, Zircwash or Z-Guard provides the least attack and adequate performance.
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From October 1998
BLUE BORON NITRIDE COATINGS ALLOW EASY VISIBILITY
OF COATING DURING APPLICATION AND USE
Standard white boron nitride coatings sometimes blend in with the normal white to cream coloring of ceramic substrates, making it difficult to tell whether or not an area is coated [such as troughs or ceramic tables]. This can even be true for uses with permanent molds, where Boron Nitride Releasecoat is used as a topcoat over an insulating undercoating. The insulating undercoating is often a white or cream color, making it difficult for the operator to determine which areas have been coated with boron nitride or when touchups are necessary. Therefore, ZYP Coatings introduced special, permanently-colored (BLUE) boron nitride coatings
The blue color additive is compatible with molten aluminum and other nonferrous metals and retains its color during metal processing operations. Thus, it is easy to tell when an area has been painted with boron nitride and also to tell when the boron nitride is no longer present (or re-coating is needed). This development improves the coating application and maintenance for many processes.
BORON NITRIDE LUBRICOAT BLUE – for troughs, launders, runners,
and other ceramic components
BORON NITRIDE RELEASECOAT-BLUE – for permanent mold applications
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From July 1998
BN-AEROSOL [BORON NITRIDE AEROSOL LUBRICOAT] IS
THE MOST VERSATILE FOR ALL SPECIALTY USES
The properties of boron nitride are unique: excellent lubricity; non-wetting with molten metals; stability with molten glasses and slags; excellent electrical insulation; high thermal conductivity; resistance to molten salts; use-temperatures of over 1000 C in any atmosphere; superior chemical resistance; microwave transparency. Its lubrication capability is superior to graphite, since boron nitride maintains its lubricity in vacuum and/or cryogenic conditions and since boron nitride does not oxidize readily like graphite. Therefore, boron nitride is ideal for application as a coating wherever anti-stick, reaction-barrier, or molten-metal-resistant conditions are needed on substrates that do not alone meet the needed requirements - whether the substrate is ceramic, metal, graphite, or virtually anything. ZYP Coatings, Inc. produces BN-Aerosol that provides all the unique properties of BN while also providing the easy-to-use convenience of an aerosol can. Uniform, fast-drying, thin boron nitride coatings can now be applied by anyone. BN-Aerosol is available in an economical 13 oz. can, which is often used for initial testing. For scaled-up/industrial uses, the BN-AEROSOL-BRUSHABLE [the same formulation as used in the 13-oz. can but in "bulk" form] can be applied by brush, dip, or pressurized air-spray such as normally used for larger scale uses.
Applications are diverse -- crucible/mold coatings for molten nonferrous metals (aluminum, zinc, magnesium); non-stick coatings for ladles, stalk tubes, troughs, launders; release agent for hot-pressing of ceramics; release for glass forming operations; spatter release for welding; brazing stop-off; isothermal forming of special alloys. Therefore, the title of "versatile" is most appropriate for boron nitride and also for BN-Aerosol.
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From January 1998
COATINGS FOR METAL SURFACES PROVIDE LONG-TERM PROTECTION
When long-term protection from metal oxidation and chemical attack is required, there are several products offered by ZYP Coatings that are applicable –
SEALMET – a dark-colored, hard coating, useful to 1300 C (2800 F).
CODEMARK – white, green, or black colors available; a hard coating that is useful to 900 C (1650 F) or higher, used for "ID" (identification) coding and marking.
HE-2700; green, high-emissivity, hard coating for 1000 C (1800 F) long-term uses and up to 1300 C for short-term uses.
All these coatings are ready-to-use, water-based, and easy-to-apply – like house paint. Only a thin layer is needed, thus giving a coverage of over 250 square feet per gallon. High-temperature stability of these coatings is such that they do not glaze, melt, run, become tacky, or chalk off.
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From Dec. 1997
COATINGS FOR SPECIALTY GLASS PROCESSING
CAN AVOID THE NEED FOR PLATINUM
For the specialty glass industry, several of ZYP Coatings, Inc. paintable coatings have been shown to be effective:
To 1200 C: Yttrium Oxide ("Y-Aerosol" or "Y-Aerosol-Brushable", which are 98% yttrium oxide on heating) Coating is stable with high- lead as well as lead free glasses. This coating is non-aqueous and is the best yttrium oxide coating for air environments.
For temperatures to 1200 C with LEAD FREE glasses, ZIRCWASH (97% zirconium oxide, 3% aluminum oxide on heating) provides the best adherent, non-reactive coating. ZIRCWASH is water-based, excellent for air usage.
These coatings are quite adherent to aluminum oxide, quartz, and most other high-temperature substrates. They represent an easy way to avoid reactions with molten glasses and their slags.
Some other coatings that have found uses in glass processing are:
• For reducing/preventing oxidation for all graphite items to over 1000 C, the silicon-carbide-based materials COVERGUARD and MW-50 are excellent.
• For reducing/preventing oxidation and gas reactions up to 1300 C with virtually any type of steel parts, the long-term-use coating, SEALMET, is applicable.
All these coatings are ready-to-use and easy to apply.
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From Nov. 1997
TRIBOCOR
This unique material which has excellent corrosion and wear resistance is now handled by
MATTEC LLC. Please
contact Dr. William Snyder via
email for more information
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From September 1997
REFRACTORY CERAMICS AVAILABLE IN A CONVENIENT AEROSOL SPRAY CAN
*Y2O3 *ZrO2 *Al2O3 *TiN * BN
ZYP Coatings, Inc. produces easy-to-apply aerosol formulations of the most widely used ceramic materials. These coatings allow tailoring of surfaces to provide useful properties -- including thermal conductivity, electrical conductivity, lubrication, resistance to molten metals, etc. Zirconia provides the lowest thermal conductivity ceramic, whereas titanium nitride is a very high thermal conductivity material. Aluminum oxide and boron nitride are excellent electrical insulators to very high temperatures, whereas titanium nitride is an electrical conductor. Boron nitride provides excellent lubricity as well as resistance to molten nonferrous metals, molten salts, slags, glasses, etc. Yttrium oxide is the thermodynamically most stable oxide and is the foremost material for the most demanding reactive-material/ interaction investigations. The convenient aerosol cans allow spraying onto all types of surfaces -- ceramic, metal, graphite, or others, including flexible substrates. These aerosols provide uniform, thin, fast-drying, protective high-temperature coatings that have many varied applications (i.e., anti-stick layers, barrier stop-offs, etc.). Use-temperatures of the aerosols extend up to 1900 C, and they are usable in most any atmosphere. For each of these aerosols, an “AER-BRUSHABLE” or “bulk” paint form [like ordinary house paint] utilizing the same system as for the aerosol cans is offered – allowing scale-up for in-house air-spray systems or brushing/dipping application.
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From July 1997
MAKE YOUR OWN CUSTOM PAINT OR PASTE
There are many instances where customers wish to use exotic, special materials (microspheres, fibers, toxic or radioactive substances) for high-temperature work. For these cases, ZYP Coatings offers paint binders/suspension-agents that can accommodate most any material. Water-stable materials can be used with the water-based binder/suspension-agents, whereas water-reactive materials can generally be used with the non-aqueous-based binder/suspension-agents. The pH of the water-based systems can be chosen as neutral, acidic, or basic -- to prevent reactions with desired additives. Upper use-temperatures of these binder/suspension-agent systems vary from 1100 to 2000 C. Final hardness and purity of the final coating are other considerations for choosing the binder/suspension system for a particular material. However, these systems are very user-friendly, requiring only that the material be added to the binder/suspension-agent liquid and mixed to achieve the desired consistency. Our LINKS section will direct you to some sites which supply many specialty inorganic materials that can be made into a coating. The "Make Your Own Custom Paint"datasheet has further information on this subject and specifics on the binder-suspension-agent liquids.
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From June 1997
YTTRIUM OXIDE FOR THE MOST DEMANDING HIGH-TEMPERATURE APPLICATIONS TO OVER 2000C
ZYP Coatings offers a complete line of paintable yttrium oxide coatings, which have proven superior to all other high-temperature coatings for maximum resistance to aggressive, reactive materials. Yttrium oxide coatings are ideal for crucible and mold coatings for molten uranium, titanium alloys, chromium, beryllium, etc. The yttrium oxide coatings are also excellent reaction barriers (for masking, spatter-release, and stop-off needs) in diffusion bonding, welding, and brazing -- causing no "alpha-case" problems with titanium. Also, since yttrium oxide is soft and lubricating at high temperatures, these coatings are useful for specialty forming operations such as superplastic forming or isothermal forging and back-extrusion of titanium, specialty steels, and reactive alloys. Electrically and thermally insulating to 2000 C, yttrium oxide coatings provide uniqueness for many areas needing these characteristics. Both water-based and solvent-based coatings are available along with a convenient aerosol form.
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From May 1997
COMPLETE REPAIR AND PROTECTION OF GRAPHITE PARTS FROM OXIDATION/REACTION
MW-50 PASTE from ZYP Coatings is a fiber-strengthened, silicon-carbide-based paste that can be troweled to form a thick, stucco-like shell on all types of graphite parts -- providing a hard, wear-resistant/abrasion-resistant layer that is non-reactive to most molten metals. MW-50 can be built up to most any thickness -- ideal for repairing graphite sections that have been severely eroded or damaged, thus saving expensive replacement. The MW-50 stops graphite oxidation to over 1000 C (over 1800 F), extending the use of graphite in air to these higher temperatures. When a coating is desired (i.e., for lesser-eroded areas of graphite parts), COVERGUARD is a coating that applies like house paint to all graphite/carbon surfaces and also stops oxidation to over 1000 C. These products have high emissivity and are thermal-shock-resistant, withstanding cyclic use. Both these products are water-based and easy to use.
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From April 1997
BRAZE STOP-OFF AND WELD SPATTER RELEASE
ZYP Coatings' Braze Stop-Off materials effectively keep braze alloys from touching and brazing metal parts. They also act as release coatings to prevent metal sticking during heat treatments. Braze Stop-25 is a white concentrated water-based paint which provides a house-paint-like coating thickness after drying. This also is available in a water-based paste version, Braze Stop Paste-25, that is useful for filling gaps, holes, and milled areas. Also, Braze Stop Aerosol-25 is a fast-drying, easy-to-use, solvent-based aerosol version of the stop-off paint.
Weld Spatter Release paint, Weld Release 25, provides Teflon¨-like release of weld spatter for both fixtures and gun nozzles:
Both the Braze Stop-Off and Weld Spatter Release coatings are easy to use, like ordinary house paint. These coatings have use-temperatures to 1000 C (over 1800 F) in air and to higher temperatures in inert or vacuum environments.
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From March 1997
PAINTABLE ALUMINUM OXIDE COATINGS AND CODEMARK
ZYP Coatings' two water-based aluminum oxide (or alumina) coatings are designed for specialty research and development uses. Type A-1 Coating is an alumina bonded alumina paint -- yielding 100% Al2O3 upon drying. Type A-2 Coating is a silica-free formula that yields a very hard, abrasion- resistant coating -- still having high alumina content/purity: it is ideal for multiple use, high-wear-resistant applications. Additionally, a solvent-based aerosol version, A-Aerosol, is offered along with the “bulk” paint version of the aerosol [A-Aerosol-Brushable]. The special properties of alumina, such as its excellent electrical insulating capabilities and stability in many environments to very high temperatures, often make it an excellent candidate coating.
Codemark coatings are ideal for marking and identifying applications in areas of high temperature usages (up to temperatures of >980 C or >1800 F). Available in white, green, and black, Codemark can be applied to all metals, ceramics, and graphite surfaces. Also, Codemark resists abrasion and is resistant to attack by oxidation and gases, molten metal slags and fluxes -- surviving multiple heating/cooling cycles.
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