Method of coating and protecting coal tip burner with colloidal silica based high temperature and abrasion resistant putty
A wear resistant substrate including a metal substrate having a surface, a reinforcing support attached to the surface and cured reaction products of an inorganic curable composition disposed over and through the reinforcing support and bonded to the surface. Also a method of enhancing the wear resistance of a metal surface by attaching a reinforcing support to the surface; disposing an inorganic curable composition over and through the reinforcing support and into contact with the surface; and curing the composition.
1. A coal burner including a wear resistant composite, comprising:
a metal substrate having a surface;
a reinforcing support attached to the surface; and
an inorganic curable composition disposed over and through the reinforcing support and contacting the surface, wherein the curable composition comprises a binder part comprising at least one of colloidal silica and alkaline silicate; a filler and aggregate part comprising at least one of alumina powder, ceramic powder, ceramic fiber, metal powder, silicon carbide powder, silica powder, ceramic bead, metasilica and metal oxides, and a cross-linker part comprising at least one of magnesium oxide (MgO),sodium dihydrogen orthophosphate (Na 2 HPO 4 ), sodium silica fluoride (Na 2 SiF 6 ), and sodium borate.
2. The wear resistant composite of claim 1 wherein the curable composition further comprises fluid.
3. The wear resistant composite of claim 1 wherein the reinforcing support comprises a grid of spaced metal elements.
4. The wear resistant composite of claim 1 wherein the reinforcing support comprises a metal mesh.
5. The wear resistant composite of claim 1 wherein the inorganic curable composition is cured and bonded to the surface.
6. The composition of claim 1 being devoid of organic gelation agents.
7. The composition of claim 1 being devoid of organic gelation agents selected from at least one of formaldehyde, formamide, paraformaldehyde, glyoxal, methyl formate, methyl acetate, ethyl formate and ethyl acetate.
8. A wear resistant composite, comprising:
a metal substrate having a surface;
a reinforcing support attached to the surface; and
an inorganic curable composition disposed over and through the reinforcing support and contacting the surface, wherein the curable composition comprises a binder part comprising at least one of colloidal silica and alkaline silicate; a filler and aggregate part comprising alumina powder, ceramic beads larger than 0.1 inches and metal powder; and a cross-linker part comprising at least one of magnesium oxide (MqO); sodium dihydrogen orthophosphate (Na 2 HPO 4 ); sodium silica fluoride (Na 2 SiF 6 ); and sodium borate.
9. A method of enhancing the wear resistance of a metal surface, comprising:
attaching the reinforcing support of claim 8 to the surface;
disposing the inorganic curable composition of claim 8 over and through the reinforcing support and into contact with the surface; and
curing the inorganic curable composition.
10. The wear resistant composite of claim 8 wherein the alkaline silicate is selected from at least one of calcium silicate, magnesium silicate, potassium silicate and sodium silicate.
11. The wear resistant composite of claim 8 wherein the inorganic curable composition comprises 10 to 70 parts by weight of the binder part; 40 to 245 parts by weight of the filler and aggregate part and 0.05 to 15 parts by weight of the cross-linker part.
12. The wear resistant composite of claim 8 wherein the inorganic curable composition consists of the binder part; the filler and aggregate part, the cross-linker part and optionally fluid.
13. The wear resistant composite of claim 8 wherein the inorganic curable composition is cured and bonded to the surface.