Fusion of glass/ceramic to industrial metallic substrates

A method of fusing ceramic to an industrial metallic substrate, comprising:

• a) treating a metallic substrate having a passivated surface thereon to remove the passivated surface layer of the metallic substrate;
• b) removing the abrasion residue off the metallic substrate resulting, after the treating step a);
• c) coating the metallic substrate of step b) with a suspension of ceramic powders in a solvent comprising glycerin;
• d) inserting the wet-coated metallic substrate of step c) into a furnace chamber with a non-reactive atmosphere;
• e) purging the furnace chamber with an inert gas to substantially remove any other gas within the chamber;
• and
• f) heating and cooling the wet coated metallic substrate inside the chamber in the inert gas, to form a metallic substrate having a ceramic layer bonded thereon.

A method of fusing a vitrified ceramic to a metallic substrate, comprising:

• a) grit blasting the surface layer of a metallic substrate, and having a surface layer with aluminum oxide to remove the surface layer of the steel substrate to minimize the introduction of active foreign particles;
• b) cleaning the metallic substrate, after the grit blasting of step a);
• c) depositing a suspension of ceramic powders in a solvent onto the metallic substrate resulting from step b) with an air brush until the metallic substrate is fully coated;
• d) air drying the coated metallic substrate of step c);
• e) inserting the dried coated substrate of step d) into a non-reactive chamber of a furnace with a controlled atmosphere;
• f) purging the chamber with an inert gas to substantially remove any other gas within the chamber;
• and
• g) firing the dried coated metallic substrate inside the chamber in the inert gas, whereby a metallic substrate having a vitrified ceramic fused thereon is formed.

A method of fusing vitrified ceramic to a metallic substrate, comprising:

• a) removing the surface layer of the metallic substrate having a surface layer thereon;
• b) coating the metallic substrate resulting from step a) with a suspension of glass-ceramic particles in a solvent;
• c) drying the suspension coated metallic substrate of step b);
• d) inserting the dried coated metallic substrate of step c) into a non-reactive chamber of an atmospheric furnace,
• e) purging the chamber with an inert gas to substantially remove any other gas within the chamber;
• f) heat processing the coated metallic substrate inside the chamber to at least a ceramic transition temperature of the ceramic, in the inert gas;
• and
• g) cooling the coated metallic substrate to minimize stress between the coating and the metallic substrate, thereby forming a metallic substrate having a vitrified ceramic fused thereon.