Ceramic Alloy Powders for Thermal Spray, Plasma Spray, Wear-Resistant, Thermal Barrier & Industrial Protective Coatings
Product Overview
GREENSTONE Ceramic Alloy Powders are engineered ceramic powder materials designed for thermal spraying, atmospheric plasma spraying (APS), flame spraying, protective surface coating and advanced surface engineering applications.
The product portfolio covers a broad range of oxide ceramic systems, including alumina (Al₂O₃), alumina-titania (Al₂O₃-TiO₂), chromium oxide (Cr₂O₃), titanium dioxide (TiO₂), titania-chromia (TiO₂-Cr₂O₃), yttria-stabilized zirconia (ZrO₂-Y₂O₃), magnesia-stabilized zirconia (ZrO₂-MgO), silica-modified zirconia (ZrO₂-SiO₂) and other engineered ceramic compositions.
These powders are developed to produce functional coatings with different combinations of wear resistance, abrasion resistance, thermal resistance, electrical insulation, corrosion resistance, thermal shock resistance and surface hardness.
GREENSTONE ceramic powders are suitable for surface engineering applications across the aerospace, energy, power generation, petrochemical, machinery, textile, automotive, electronics, metal processing, industrial maintenance and general manufacturing industries.
Different ceramic compositions and particle-size distributions can be selected according to the coating process, substrate material and required coating properties.
Broad Ceramic Material Portfolio
GREENSTONE supplies multiple oxide ceramic powder systems covering applications from conventional wear-resistant coatings to high-temperature thermal barrier coatings. Available material families include:
Al₂O₃ Ceramic Powder
High-purity alumina provides excellent hardness, electrical insulation, wear resistance and high-temperature stability. It is widely used for electrically insulating coatings, wear-resistant surfaces and industrial component protection.
Al₂O₃-TiO₂ Ceramic Powder
Alumina-titania combines the hardness of alumina with improved toughness. By adjusting TiO₂ content, coating hardness, toughness, wear resistance and friction characteristics can be balanced for different applications.
Cr₂O₃ Ceramic Powder
Chromium oxide produces dense, hard coatings with excellent wear, friction and corrosion resistance. It is particularly suitable for components exposed to sliding wear, abrasive environments and demanding industrial service.
TiO₂ Ceramic Powder
Titanium dioxide offers good coating density, bonding characteristics and wear properties and may be used independently or as a component of composite ceramic systems.
TiO₂-Cr₂O₃ Ceramic Powder
Titania-chromia compositions provide enhanced coating wear resistance and can be selected for demanding friction and abrasion applications.
ZrO₂-Y₂O₃ Ceramic Powder
Yttria-stabilized zirconia is one of the principal ceramic materials used for thermal barrier coatings. Its low thermal conductivity and thermal-shock resistance make it suitable for components exposed to elevated temperatures.
ZrO₂-MgO Ceramic Powder
Magnesia-stabilized zirconia combines thermal insulation capability with thermal stability and is used for high-temperature protective coatings.
ZrO₂-SiO₂ Ceramic Powder
Silica-modified zirconia systems provide useful thermal and corrosion-resistant properties for specialized protective coating applications.
Key Advantages
High Wear and Abrasion Resistance
Selected alumina, alumina-titania and chromium oxide systems provide hard protective surfaces capable of extending component service life under abrasive and sliding wear conditions.
High-Temperature Protection
Zirconia-based ceramic powders can be used to produce thermal barrier and heat-resistant coatings for components exposed to elevated operating temperatures.
Electrical Insulation
High-purity alumina coatings provide excellent electrical insulating properties for electrical, electronic and industrial equipment.
Corrosion and Chemical Resistance
Dense oxide ceramic coatings can provide additional protection against corrosive environments and chemical attack, depending on material selection and coating architecture.
Adjustable Hardness and Toughness
Different Al₂O₃-TiO₂ ratios allow coating properties to be optimized between high hardness and improved toughness.
Controlled Particle Size
Standard thermal-spray powder particle sizes can be supplied, with 15–45 μm available for the product families represented here. Other distributions can be prepared according to process requirements.
Good Powder Flowability
Controlled particle morphology and particle-size distribution support stable powder feeding and consistent deposition during suitable thermal spray processes.
Industrial Application Range
Typical applications include pump components, shafts, rollers, textile machinery, sealing surfaces, electrical insulation components, wear parts, high-temperature components and industrial repair applications.
Typical Processing Technologies
GREENSTONE ceramic powders can be supplied for applications including:
- Atmospheric Plasma Spray (APS)
- Thermal Spray Coating
- Flame Spray
- Ceramic Protective Coating
- Wear-Resistant Coating
- Electrical Insulation Coating
- Thermal Barrier Coating (TBC)
- Corrosion-Resistant Coating
- Surface Engineering and Industrial Remanufacturing
Process note: Not every ceramic composition is suitable for every deposition technology. Powder chemistry, morphology and particle-size distribution should be selected according to the actual spraying system and coating requirements.
| International Material / Composition | Typical Composition | Standard Particle Size | Main Properties | Typical Industrial Applications |
|---|---|---|---|---|
| Al₂O₃ | >99% Al₂O₃ | 15–45 μm | High hardness, electrical insulation, wear resistance, high-temperature stability | Electrical insulation, wear protection, industrial machinery, high-temperature components |
| Al₂O₃-3TiO₂ | Al₂O₃ + ~3% TiO₂ | 15–45 μm | Hard, dense coating, good wear and heat resistance | Wear-resistant surfaces, machinery components, industrial rollers |
| Al₂O₃-13TiO₂ | Al₂O₃ + ~13% TiO₂ | 15–45 μm | Balanced hardness and toughness, good abrasion resistance | Shafts, sleeves, pump parts, general wear protection |
| Al₂O₃-30TiO₂ | Al₂O₃ + ~30% TiO₂ | 15–45 μm | Improved toughness, good friction and wear characteristics | Sliding surfaces, textile machinery, mechanical wear components |
| Al₂O₃-40TiO₂ | Al₂O₃ + ~40% TiO₂ | 15–45 μm | Tough ceramic coating, reduced brittleness, wear resistant | Machinery, textile equipment, wear and friction surfaces |
| Al₂O₃-50TiO₂ | Al₂O₃ + ~50% TiO₂ | 15–45 μm | Tough coating, good wear resistance | Industrial wear parts and mechanical components |
| Al₂O₃-Cr₂O₃ | Al₂O₃ + Cr₂O₃ | 15–45 μm | Hard, wear resistant, high-temperature resistant | Heavy-duty wear protection and industrial machinery |
| Al₂O₃-ZrO₂ | Al₂O₃ + ZrO₂ | 15–45 μm | Improved toughness and thermal resistance | Thermal and wear-resistant industrial coatings |
| Al₂O₃-MgO | Al₂O₃ + MgO | 15–45 μm | Thermal resistance and thermal-shock performance | High-temperature protective surfaces |
| Al₂O₃-SiO₂ | Al₂O₃ + SiO₂ | 15–45 μm | Wear and corrosion resistance | Industrial protective and corrosion-resistant coatings |
| Cr₂O₃ | >99% Cr₂O₃ | 15–45 μm | Very high hardness, wear resistance, low friction, corrosion resistance | Pump seals, shafts, rollers, wear surfaces, machinery |
| TiO₂ | >99% TiO₂ | 15–45 μm | Dense coating, good bonding and wear characteristics | General industrial ceramic coatings |
| TiO₂-Cr₂O₃ | TiO₂ + Cr₂O₃ | 15–45 μm | Enhanced abrasion and friction resistance | Wear-intensive mechanical components |
| ZrO₂-8Y₂O₃ (8YSZ) | ZrO₂ + ~8 wt.% Y₂O₃ | 15–45 μm* | Low thermal conductivity, thermal-shock resistance, high-temperature protection | Thermal barrier coatings, energy and high-temperature machinery |
| ZrO₂-20Y₂O₃ | ZrO₂ + ~20 wt.% Y₂O₃ | 15–45 μm* | High-temperature ceramic functionality and thermal stability | Specialized thermal and functional coatings |
| ZrO₂-MgO | ZrO₂ + MgO | 15–45 μm* | Thermal insulation, thermal-shock resistance | High-temperature components and protective coatings |
| ZrO₂-SiO₂ | ZrO₂ + SiO₂ | 15–45 μm* | Thermal and corrosion-resistant ceramic coating | Specialized industrial protective coatings |
Particle size can be customized according to the selected thermal spray process and equipment.
General Supply Specifications
| Parameter | Typical Specification |
|---|---|
| Product Category | Oxide Ceramic Powder / Ceramic Alloy Powder |
| Main Material Systems | Al₂O₃, Al₂O₃-TiO₂, Cr₂O₃, TiO₂, ZrO₂-Y₂O₃, ZrO₂-MgO, ZrO₂-SiO₂ |
| Typical Particle Size | 15–45 μm |
| Optional Particle Size | Customized according to coating process |
| Powder Characteristics | Controlled particle-size distribution, good flowability and stable feeding |
| Primary Processes | APS, thermal spray, flame spray and related ceramic coating processes |
| Primary Functions | Wear resistance, thermal protection, electrical insulation, corrosion resistance |
| Industries | Aerospace, energy, power generation, petrochemical, machinery, textile, automotive, electronics and industrial maintenance |
| Customization | Composition and particle-size distribution available according to application requirements |
| Brand | GREENSTONE |
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