Corrosion resistant coating for a high temperature heat exchanger

Abstract

A method of manufacturing a high temperature heat exchanger that includes providing a heat exchanger made of at least one of nickel and a nickel metal alloy, applying a silicone aluminum coating to the heat exchanger, drying the silicone aluminum coating at a first temperature for a first time period, and curing the silicone aluminum coating at a second temperature for a second time period, such that a ceramic coating is formed.

1 . A method of coating a metal substrate, comprising:
 applying a silicone aluminum coating to a metal substrate;   drying the silicone aluminum coating at a first temperature for a first time period; and   curing the silicone aluminum coating at a second temperature for a second time period, the second temperature being greater than the first temperature and the second time period being greater than the first time period.   
     
     
       2. The method of  claim 1 , wherein the first temperature is 300° F. (149° C.). 
     
     
       3. The method of  claim 1 , wherein the second temperature is 1200° F. (650° C.). 
     
     
         4 . The method of  claim 1 , wherein the second time period is four hours. 
     
     
         5 . The method of  claim 1 , wherein the silicone aluminum coating includes aluminum particles combined with at least one of a silicone polymer emulsion and a silicone resin emulsion. 
     
     
         6 . The method of  claim 1 , wherein the metal substrate is a nickel metal heat exchanger. 
     
     
         7 . The method of  claim 1 , wherein curing the silicone aluminum coating at a second temperature for a second time period converts the silicone aluminum coating to a ceramic coating. 
     
     
         8 . The method of  claim 7 , wherein the ceramic coating has a thickness of less than 1 mil (0.0254 mm). 
     
     
         9 . A method of manufacturing a high temperature heat exchanger, comprising:
 providing a heat exchanger made of at least one of nickel and a nickel metal alloy;   applying a silicone aluminum coating to the heat exchanger;   drying the silicone aluminum coating at a first temperature for a first time period; and   curing the silicone aluminum coating at a second temperature for a second time period, such that a ceramic coating is formed.   
     
     
         10 . The method of  claim 9 , further comprising: cleaning the heat exchanger. 
     
     
         11 . The method of  claim 9 , further comprising: removing excess silicone aluminum coating. 
     
     
         12 . The method of  claim 9 , wherein the second temperature is greater than the first temperature and the second time period is greater than the second time period. 
     
     
         13 . The method of  claim 9 , wherein the second temperature is greater than 800° F. (427° C.). 
     
     
         14 . The method of  claim 9 , wherein the second temperature is at least 1200° F. (650° C.). 
     
     
         15 . The method of  claim 9 , wherein the silicone aluminum coating includes aluminum particles combined with at least one of a silicone polymer emulsion and a silicone resin emulsion. 
     
     
         16 . The method of  claim 9 , wherein the ceramic coating has a thickness of less than 1 mil (0.0254 mm).