Abstract: A process for applying an insulating bonded refractory fiber layer to a substrate such that the bonded refractory fiber will not delaminate form the substrate it is adhered to during thermal cycling. A pre-coat layer of refractory fiber coated with a binder containing potassium silicate, colloidal silica, kaolin clay, hydrated alumina, and optionally, Xanthan gum is applied to a substrate, preferably by spray application. Then a second insulating layer of refractory fiber coated with a binder containing either colloidal alumina, colloidal silica, colloidal zirconia, aluminum phosphates, or mixtures thereof is applied to the pre-coated substrate, preferably by spray application. Finally, the coated layers of bonded refactory fibers are cured. An article comprising a refractory layer bonded to a substrate produced by the foregoing process is also disclosed.

Abstract: A method for spray applying refractory fiber to a surface. An alumina containing binder, preferably aluminum chloride, is used in a spray method to bond the fiber to itself and to a substrate surface. A refractory layer comprised of fiber and binder produced by the method of the invention is also disclosed.