METAL ALLOYS - OVERVIEW
Ferrous Alloys
The use of different grades of steel throughout heavy industrial plants is dictated by material capabilities and economics. HTP-100 coated low grade and inexpensive ferrous alloys typically outperform their higher-grade counterparts, thus offering opportunities for OEMs to lower capital costs by using inexpensive ferrous alloys.
Common uses include:
- Preventing Molten Metal Corrosion
- HTP-100 is stable against non-ferrous molten metals such as aluminum and magnesium which can accelerate corrosion of steels. HTP-100 is a "non-stick" coating.
- Preventing surface carburization
- HTP-100 is an effective diffusion barrier against carburization in hydrocarbon gas environments at elevated temperatures.
- Preventing Steam Corrosion
- High temperature steam can cause rapid corrosion of ferrous alloys. HTP-100 serves as an effective high temperature diffusion barrier against steam.
Other Alloys
Nickel and titanium alloys are used for specialty high temperature applications, particularly in the aerospace sector. Protection of these alloys while offering high emissivity characteristics is essential for thermal management. HTP-100 is an effective barrier against oxidation and stable under vacuum conditions without outgassing and thus retains its emissivity.
Check out demonstrations of uses on our Blog.
REFRACTORIES & CERAMICS - OVERVIEW
Lower-Cost Refractories
- Industrial refractory ceramics are used as thermal insulators and chemical barriers in industries such as fertilizer production, cement manufacturing, and metal casting, with various compositions and porosities depending on end use.
- High alumina content, dense refractories have the best corrosion resistance and thermal stability of all refractories, but they are expensive.
- Insulating fire bricks (IFBs) are much cheaper, are better thermal insulators, and are easier to machine and install, but are highly porous and are more susceptible to degradation at high temperatures.
- HTP-100 protects IFBs from chemical degradation, enabling the use of these low-cost materials in demanding environments, such as molten chloride salts at 1500°F.
Energy Savings
- A further benefit of applying HTP-100 on refractory ceramics is its high emissivity, which allows the coating to re-radiate heat into the process, generating energy savings and improving thermal uniformity over the refractory surface, thereby preventing hot spots.
Abrasion Resistance
- The combination of chemical corrosion and mechanical erosion means that refractory ceramics must be replaced frequently due to material loss. HTP-100 protects against both corrosion and erosion, with a mechanically tough and hard coating for long term durability. HTP-100 can withstand typical tool drop impacts.
Chemical Durability
- Most coatings for industrial refractories are high-pH silicate coatings, which can be hazardous to handle and will react with refractories and the environment at high temperatures, leading to degradation of both the coating and the refractory. HTP-100 is an inert coating that is stable up to 1800°F, due to its highly stable aluminum phosphate matrix.
Crack Sealing
- HTP-100 can be used to seal cracks in refractory bricks, which can develop over time due to sintering and hot corrosion. HTP-100 is easily applied during maintenance shutdowns, and, once dried, can be cured in service.
Check out demonstrations of uses on our Blog.
Specialty Substrates - OVERVIEW
HTP-100 is an all-purpose coating, and our customers are continuing to find new ways in which it can solve high-temperature and extreme environment material challenges.
HIGH TEMPERATURE ADHESIVE
HTP-100 can serve as a high-temperature adhesive in certain applications. It can be sprayed on both mating surfaces, which are then joined and fired to 570°F to achieve a durable high temperature joint capable of 1800°F, with at least 100 psi adhesive bond strength.
WELD PROTECTION
While welds and brazes can corrode under ambient atmospheric conditions, they are highly susceptible to corrosion in high-temperature plant infrastructure due to their complex morphology and metallurgy. HTP-100 can provide effective galvanic corrosion protection under ambient conditions, and it is especially effective in protecting welds and brazes at high temperatures, where rapid oxidation can weaken the joint significantly
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Coated (left) and uncoated (right) 316 stainless steel weld joints, 72 hours at 1500°F in ambient air, with 3 thermal cycles – coating remained intact and protected substrate from oxidation.
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Check out demonstrations of uses on our Blog.
