EP0302465A2 - Verfahren zur keramischen Beschichtung von Metallen - Google Patents
Verfahren zur keramischen Beschichtung von Metallen Download PDFInfo
- Publication number
- EP0302465A2 EP0302465A2 EP88112601A EP88112601A EP0302465A2 EP 0302465 A2 EP0302465 A2 EP 0302465A2 EP 88112601 A EP88112601 A EP 88112601A EP 88112601 A EP88112601 A EP 88112601A EP 0302465 A2 EP0302465 A2 EP 0302465A2
- Authority
- EP
- European Patent Office
- Prior art keywords
- coating
- ion
- ceramic
- grams
- ceramic coating
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
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- 238000000034 method Methods 0.000 title claims abstract description 49
- 229910052751 metal Inorganic materials 0.000 title claims abstract description 47
- 239000002184 metal Substances 0.000 title claims abstract description 47
- 238000005524 ceramic coating Methods 0.000 title claims abstract description 45
- 150000002739 metals Chemical class 0.000 title claims description 10
- 238000000576 coating method Methods 0.000 claims abstract description 46
- 239000011248 coating agent Substances 0.000 claims abstract description 45
- 239000000758 substrate Substances 0.000 claims abstract description 27
- ILRRQNADMUWWFW-UHFFFAOYSA-K aluminium phosphate Chemical compound O1[Al]2OP1(=O)O2 ILRRQNADMUWWFW-UHFFFAOYSA-K 0.000 claims abstract description 23
- 239000000203 mixture Substances 0.000 claims description 19
- 238000011282 treatment Methods 0.000 claims description 17
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 claims description 14
- 229910000147 aluminium phosphate Inorganic materials 0.000 claims description 14
- 238000006243 chemical reaction Methods 0.000 claims description 12
- 230000003647 oxidation Effects 0.000 claims description 12
- 238000007254 oxidation reaction Methods 0.000 claims description 12
- 229910052782 aluminium Inorganic materials 0.000 claims description 11
- -1 aluminum ion Chemical class 0.000 claims description 10
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 7
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 claims description 7
- NHNBFGGVMKEFGY-UHFFFAOYSA-N Nitrate Chemical compound [O-][N+]([O-])=O NHNBFGGVMKEFGY-UHFFFAOYSA-N 0.000 claims description 5
- 229910052910 alkali metal silicate Inorganic materials 0.000 claims description 5
- 239000000377 silicon dioxide Substances 0.000 claims description 5
- 239000000126 substance Substances 0.000 claims description 5
- 229940085991 phosphate ion Drugs 0.000 claims description 4
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 3
- XTEGARKTQYYJKE-UHFFFAOYSA-M Chlorate Chemical compound [O-]Cl(=O)=O XTEGARKTQYYJKE-UHFFFAOYSA-M 0.000 claims description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 2
- 229910052783 alkali metal Inorganic materials 0.000 claims description 2
- 229940005989 chlorate ion Drugs 0.000 claims description 2
- 229910001453 nickel ion Inorganic materials 0.000 claims description 2
- 150000001340 alkali metals Chemical class 0.000 claims 1
- 239000000919 ceramic Substances 0.000 abstract description 11
- 238000005229 chemical vapour deposition Methods 0.000 abstract description 10
- 238000004544 sputter deposition Methods 0.000 abstract description 3
- 238000007598 dipping method Methods 0.000 abstract description 2
- 238000005507 spraying Methods 0.000 abstract description 2
- 238000004519 manufacturing process Methods 0.000 abstract 1
- 238000012360 testing method Methods 0.000 description 22
- 229940009859 aluminum phosphate Drugs 0.000 description 16
- 239000007788 liquid Substances 0.000 description 14
- 239000000463 material Substances 0.000 description 14
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 9
- 235000010210 aluminium Nutrition 0.000 description 9
- 230000032798 delamination Effects 0.000 description 9
- 238000011156 evaluation Methods 0.000 description 7
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 7
- 239000000306 component Substances 0.000 description 6
- 229910000831 Steel Inorganic materials 0.000 description 5
- 230000002378 acidificating effect Effects 0.000 description 5
- 239000010959 steel Substances 0.000 description 5
- 239000008199 coating composition Substances 0.000 description 4
- 238000005260 corrosion Methods 0.000 description 4
- 230000007797 corrosion Effects 0.000 description 4
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 4
- 239000007921 spray Substances 0.000 description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 3
- 229910002651 NO3 Inorganic materials 0.000 description 3
- 229910019142 PO4 Inorganic materials 0.000 description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 3
- 239000002585 base Substances 0.000 description 3
- 229910002804 graphite Inorganic materials 0.000 description 3
- 239000010439 graphite Substances 0.000 description 3
- 150000002500 ions Chemical class 0.000 description 3
- 239000010452 phosphate Substances 0.000 description 3
- 235000011121 sodium hydroxide Nutrition 0.000 description 3
- 239000010935 stainless steel Substances 0.000 description 3
- 229910001220 stainless steel Inorganic materials 0.000 description 3
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 2
- QAOWNCQODCNURD-UHFFFAOYSA-L Sulfate Chemical compound [O-]S([O-])(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-L 0.000 description 2
- 229910010293 ceramic material Inorganic materials 0.000 description 2
- 229910052681 coesite Inorganic materials 0.000 description 2
- 229910052906 cristobalite Inorganic materials 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 230000018109 developmental process Effects 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 238000007654 immersion Methods 0.000 description 2
- 150000001247 metal acetylides Chemical class 0.000 description 2
- 150000004767 nitrides Chemical class 0.000 description 2
- 238000010422 painting Methods 0.000 description 2
- 229920001296 polysiloxane Polymers 0.000 description 2
- 238000012552 review Methods 0.000 description 2
- 229910021332 silicide Inorganic materials 0.000 description 2
- 235000012239 silicon dioxide Nutrition 0.000 description 2
- 229910052682 stishovite Inorganic materials 0.000 description 2
- 229910021653 sulphate ion Inorganic materials 0.000 description 2
- 229910052905 tridymite Inorganic materials 0.000 description 2
- 229910009112 xH2O Inorganic materials 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- QYEXBYZXHDUPRC-UHFFFAOYSA-N B#[Ti]#B Chemical compound B#[Ti]#B QYEXBYZXHDUPRC-UHFFFAOYSA-N 0.000 description 1
- CWYNVVGOOAEACU-UHFFFAOYSA-N Fe2+ Chemical compound [Fe+2] CWYNVVGOOAEACU-UHFFFAOYSA-N 0.000 description 1
- 229910020968 MoSi2 Inorganic materials 0.000 description 1
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 1
- 206010037660 Pyrexia Diseases 0.000 description 1
- 229910052581 Si3N4 Inorganic materials 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 229910033181 TiB2 Inorganic materials 0.000 description 1
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 238000007605 air drying Methods 0.000 description 1
- 239000003513 alkali Substances 0.000 description 1
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 1
- 229910021529 ammonia Inorganic materials 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000001506 calcium phosphate Substances 0.000 description 1
- 229910000389 calcium phosphate Inorganic materials 0.000 description 1
- 235000011010 calcium phosphates Nutrition 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000003518 caustics Substances 0.000 description 1
- ZCDOYSPFYFSLEW-UHFFFAOYSA-N chromate(2-) Chemical compound [O-][Cr]([O-])(=O)=O ZCDOYSPFYFSLEW-UHFFFAOYSA-N 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 238000007739 conversion coating Methods 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 238000002425 crystallisation Methods 0.000 description 1
- 230000008025 crystallization Effects 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 230000018044 dehydration Effects 0.000 description 1
- 238000006297 dehydration reaction Methods 0.000 description 1
- 238000004455 differential thermal analysis Methods 0.000 description 1
- 238000007865 diluting Methods 0.000 description 1
- BNIILDVGGAEEIG-UHFFFAOYSA-L disodium hydrogen phosphate Chemical compound [Na+].[Na+].OP([O-])([O-])=O BNIILDVGGAEEIG-UHFFFAOYSA-L 0.000 description 1
- 238000005868 electrolysis reaction Methods 0.000 description 1
- 238000005530 etching Methods 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 238000005755 formation reaction Methods 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-M hydroxide Chemical compound [OH-] XLYOFNOQVPJJNP-UHFFFAOYSA-M 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 229910000403 monosodium phosphate Inorganic materials 0.000 description 1
- 235000019799 monosodium phosphate Nutrition 0.000 description 1
- 239000007800 oxidant agent Substances 0.000 description 1
- 239000003973 paint Substances 0.000 description 1
- 229910052700 potassium Inorganic materials 0.000 description 1
- 239000011591 potassium Substances 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 238000005488 sandblasting Methods 0.000 description 1
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 description 1
- AJPJDKMHJJGVTQ-UHFFFAOYSA-M sodium dihydrogen phosphate Chemical compound [Na+].OP(O)([O-])=O AJPJDKMHJJGVTQ-UHFFFAOYSA-M 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- 238000002076 thermal analysis method Methods 0.000 description 1
- QORWJWZARLRLPR-UHFFFAOYSA-H tricalcium bis(phosphate) Chemical compound [Ca+2].[Ca+2].[Ca+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O QORWJWZARLRLPR-UHFFFAOYSA-H 0.000 description 1
- 239000002966 varnish Substances 0.000 description 1
- 238000011179 visual inspection Methods 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
- 230000004580 weight loss Effects 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/04—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C22/00—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C22/05—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions
- C23C22/06—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6
- C23C22/07—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6 containing phosphates
- C23C22/08—Orthophosphates
- C23C22/20—Orthophosphates containing aluminium cations
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/04—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material
- C23C28/042—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material including a refractory ceramic layer, e.g. refractory metal oxides, ZrO2, rare earth oxides
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D11/00—Electrolytic coating by surface reaction, i.e. forming conversion layers
- C25D11/36—Phosphatising
Definitions
- the present invention is a method for ceramic coating of metals.
- ceramic coatings with carbides such as TiC, SiC, nitrides such as TiN, Si3N4, borides such as TiB2, oxides such as Al203 or silicides such as MoSi2 can provide metals with improved heat and oxidation resistance.
- the ceramic coatings can be applied to metals by flame spray methods, ion sputtering methods, chemical vapour deposition methods (CVD), dry-in-place (coating-drying) methods, baking-in-place (coating-baking) methods and the like.
- flame spray methods ion sputtering methods, chemical vapour deposition methods (CVD), dry-in-place (coating-drying) methods, baking-in-place (coating-baking) methods and the like.
- one method is to treat a metal coated with frit at a temperature as high as 677-871°C (Jap.Pat.Publ SHO 55-26714/1980). Generally the method is carried out at a temperature used for inorganic coating materials. In the known processes the ceramic coating is applied directly on the surface of the metal which has been cleaned mechanically or chemically.
- This material comprises a denatured silicone varnish binder and alumina-silica short fibers as the ceramic material (Nikkei New Material, p.101, 5-19, 1986). According to this article, one of the advantages of the material is the capability of the film to follow the expansion of the substrate metal.
- the adhesion between the coating film and substrate metal is poor and the ceramic coatings delaminate because of the difference between the coefficient of thermal expansion of the substrate metal and the ceramic. Delamination can also be caused by oxidation of the substrate metal when exposed to high temperature.
- An object of the present invention is to provide a method for ceramic coating of metals; which coated metals can be used at high temperature without delamination.
- a further object of the invention is to provide a coating which protects the metal substrate from oxidation.
- the metal article comprising the aluminum phosphate coated metal substrate with the ceramic coating overlay also comprises the invention.
- aluminum phosphate coating refers to a film obtained by the method described in Jap.Pat.Pub.SHO 53-6945/1978 by the present applicants, wherein a coating is formed by a chemical conversion treatment or electrolytic treatment with an acidic liquid at a pH from 1.5 to 5 containing aluminum ion in a concentration of from about 0.01 to about 10 g/l and phosphate ion in about 1.0 to about 100 g/l, the principal component of such a film being aluminum phosphate (AlPO4-xH2O).
- Jap.Pat.Pub. SHO 53-6945/1978 is incorporated herein be reference.
- Publication SHO 53-6945/1978 is directed to preventing ferrous materials from corrosion by providing an alternative coating as a substitute for coatings of zinc, manganese, and calcium phosphate or the like and chromate coating for painting, and particularly for painting with acrylic-based paint.
- an aluminum phosphate coating is an excellent base coat for a ceramic coating.
- the characteristics of an aluminum phosphate coating have been investigated in more detail.
- Figure 1 shows thermal weight change and differential thermal analysis up to 500°C of an aluminum phosphate coating obtained according to the method described in the above-cited patent published herein.
- the coating of aluminum phosphate is amorphous AlPO4-xH2O, undergoes loss of x ⁇ H2O at about 150°C to 200°C (weight loss of about 12%), then up to about 500°C it is the stable form of AlPO4.
- the thermal analysis shows that the loss of adsorbed water and crystal water takes place respectively at 50-100°C and at about 150°C but at over 200°C no weight change occurs. This is an indication of the thermal stability of AlPO4.
- the drying of the aluminum phosphate coating is not critical. With air-drying of the film, residual moisture and water of crystallization are removed during baking without affecting the adhesion of the ceramic coating.
- the AlPO4 provides a base for high adhesion with the ceramic coating.
- the AlPO4 undergoes no further decomposition than the above-mentioned dehydration.
- a ceramic coating is deposited on cleaned metal surfaces according to known methods, the metal surface is oxidized when subjected to the heat resistance test and is accompanied by delamination of the ceramic coating.
- the composition containing aluminum ion for use in forming the AlPO4 coating is a liquid prepared by adding an aluminum compound such as nitrate, hydroxide or sulphate in the form of a solid or liquid to an acidic phosphate solution. The pH is adjusted so that the mixture is acidic.
- the content of aluminum ion in the mixture is from about 0.01 to 10 g/l, preferably 0.2 to 3 g/l. When less than about 0.01 g/l of Al ion is present, the deposit of aluminum phosphate is not sufficient. When the aluminum ion content exceeds about 3 g/l, economical disadvantages result.
- the acidic phosphate liquid mixture is prepared by diluting phosphoric acid, sodium dihydrogen phosphate or disodium hydrogen phosphate and the like with water so as to contain 1 to 100 g/l, preferably 5 to 50 g/l, of the phosphate ion.
- the pH is less than about 1.5, the metal being treated receives a large amount of etching.
- the pH is above about 5.0, precipitation of aluminum phosphate and aluminum hydroxide take place in the treating bath.
- nitrate ion in an amount of from 0 to about 20 g/l preferably 1 to 5 g/l, chlorate ion in an amount of from 0 to about 20 g/l preferably 1 to 5 g/l, or nickel ion in an amount of from 0 to about 5 g/l preferably 0.01 to 2 g/l. It is also useful, for the purpose of increasing coating weight, to add sulphate ion in an amount of from 0 to about 10 g/l.
- the metals to which the method of the present invention is applicable are those metallic materials which require improved heat resistance and which can be etched by phosphoric acid. Metals such as iron, steel, stainless steel, heat-resistant steel, aluminum, aluminum alloy, etc., can be treated by the method of the present invention.
- the metal substrate can be coated with the AlPO4 coating by:
- the coating formed is dried and preferably baked at a temperature above about 150°C.
- Ceramics such as carbides, nitrides, borides, oxides, silicides, mixtures or compositions containing these and the like are useful.
- Alkali metal silicate type coating compositions, metal alcoholate type coating compositions, silica sol type compositions and silicone compositions and the like can be used in the process.
- the baking-in-place (coating/baking) process of the present invention for ceramic coating can provide a coating film with adhesion to the substrate comparable to that provided by conventional CVD processes.
- the substrate becomes hot so that the heat resistance of aluminum phosphate can be utilized in the ceramic coating. Heating the substrate, during the ceramic coating, up to about 200 to about 400°C is also useful. A similar effect occurs in the ion sputtering process or flame spray process.
- Test piece SPCC steel sheet (70 x 150 x 0.8 mm) was used.
- the composition of the treating liquid was as follows: PO43 ⁇ 22.8 g/l A13+ 0.9 g/l NO3 3.1 g/l This liquid was neutralized with sodium hydroxide to adjust the pH to about 2.5.
- the metal test piece was surface cleaned and immersed in the treating liquid for 3 minutes.
- the treating liquid was maintained at a temperature of 60°C.
- the test piece was removed from the treating liquid, rinsed with water and dried. A coating weighing 1 g/m2 was formed on the test piece.
- test piece was dip-coated with GLASCA 90 (a product of Nichiban R&D Ltd., metal alcoholate type: colorless transparent, ceramic component: alkoxysilane 19-23%), then baked at 150°C for 30 minutes to form a colorless, transparent ceramic coating.
- the film thickness was 5 ⁇ m.
- An SPCC steel sheet (70 x 150 x 0.8 mm) test piece which was previously surface cleaned was subject to an electrolytic treatment in a liquid of the composition PO43 ⁇ 25.0 g/l A13+ 1.2 g/l NO3 9.0 g/l
- the liquid was neutralized with sodium hydroxide to adjust the pH to 2.5.
- the test piece was immersed in the liquid and was electrolytically treated with direct current at a temperature of 65°C, a current density of 5A/dm2 for 30 seconds.
- the opposite electrode was a graphite plate at an electrode distance of 40 mm and electrode ratio of 1:1. After the electrolytic coating, the test piece was rinsed with water and dried.
- a ceramic coating as in Example 1 was applied to the coated test piece.
- Example 1 For comparison, a ceramic coating as in Example 1 was applied to a test piece without precoating (the steel sheet was surface-cleaned with a cleaner).
- Example 1 and Example 2 were heated in an over at 250°C, 400°C or 500°C for 2 hours, then cooled in air.
- the result of an appearance inspection is shown in Table 1.
- the discoloring of the metal surface by oxidation was visually observed either through the transparent ceramic coating or, in the case the ceramic coating was delaminated, directly on such portions of the metal.
- Test pieces were coated by the conversion treatment of Example 1 or 2. The coated test pieces were then coated with various kinds of ceramic coating compositions and subjected to the following tests which results are shown in Table 3.
- test pieces After receiving the base coat and ceramic coating, test pieces were heated to various temperatures and cooled to room temperature.
- ceramic coating without precoating permits oxidation of the metal surface, often resulting in delamination.
- delamination does not take place below about 500°C and oxidation of the metal surface is suppressed.
- the heat resistance attained by means of the baking-in-place process of the invention is comparable to that obtained by a conventioned CVD process.
- the method of the present invention is free of the disadvantages of the CVD process such as long treatment time (as much as 2 to 8 hrs), poor productivity and high apparatus cost.
- the process of the invention when used with a baking-in-place process provides a simple treatment process with high productivity.
- the method of the present invention is also applicable to a CVD process and the like, and provides for excellent adhesion and oxidation resistance.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Metallurgy (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Mechanical Engineering (AREA)
- Inorganic Chemistry (AREA)
- General Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Electrochemistry (AREA)
- Other Surface Treatments For Metallic Materials (AREA)
- Chemical Treatment Of Metals (AREA)
- Laminated Bodies (AREA)
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP192591/87 | 1987-08-03 | ||
| JP62192591A JPH0730459B2 (ja) | 1987-08-03 | 1987-08-03 | 金属へのセラミックコ−ティング法 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| EP0302465A2 true EP0302465A2 (de) | 1989-02-08 |
| EP0302465A3 EP0302465A3 (de) | 1990-01-31 |
Family
ID=16293823
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| EP88112601A Withdrawn EP0302465A3 (de) | 1987-08-03 | 1988-08-03 | Verfahren zur keramischen Beschichtung von Metallen |
Country Status (5)
| Country | Link |
|---|---|
| EP (1) | EP0302465A3 (de) |
| JP (1) | JPH0730459B2 (de) |
| AU (1) | AU606726B2 (de) |
| BR (1) | BR8803842A (de) |
| MX (1) | MX170165B (de) |
Cited By (18)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0991365A4 (de) * | 1997-04-30 | 2000-04-12 | Medquest Products Inc | Elektrochirurgische klinge mit einem leitenden nicht klebendem überzug |
| WO2005061218A1 (en) * | 2003-11-19 | 2005-07-07 | Applied Thin Films, Inc. | Aluminum phosphate compounds, compositions, materials and related metal coatings |
| DE10014035B4 (de) * | 2000-03-22 | 2006-07-13 | Electro Chemical Engineering Gmbh | Gefärbte Konversionsschicht, eine Lösung zu ihrer Herstellung sowie ihre Verwendung |
| EP1743955A2 (de) | 2005-07-15 | 2007-01-17 | NHK Spring Co., Ltd. | Stahlteil mit hervorragendem Korrosionswiderstand und Korrosionsermüdungswiderstand, sowie Oberflächendbehandlung zur Herstellung |
| US7311944B2 (en) | 2002-12-23 | 2007-12-25 | Applied Thin Films, Inc. | Aluminum phosphate coatings |
| US7678465B2 (en) | 2002-07-24 | 2010-03-16 | Applied Thin Films, Inc. | Aluminum phosphate compounds, compositions, materials and related metal coatings |
| US7682700B2 (en) | 2002-08-14 | 2010-03-23 | Applied Thin Films, Inc. | Aluminum phosphate compounds, compositions, materials and related composites |
| US7887917B2 (en) | 2005-06-30 | 2011-02-15 | Unifrax I Llc | Inorganic fiber |
| CN103044995A (zh) * | 2013-01-28 | 2013-04-17 | 陈立晓 | 一种柴油机排气管道高温涂料 |
| US8497018B2 (en) | 2010-01-27 | 2013-07-30 | Applied Thin Films, Inc. | High temperature stable amorphous silica-rich aluminosilicates |
| CN103741195A (zh) * | 2013-12-23 | 2014-04-23 | 南通恒新金属工艺科技有限公司 | 钢丝电解磷化处理装置 |
| US9556063B2 (en) | 2014-07-17 | 2017-01-31 | Unifrax I Llc | Inorganic fiber with improved shrinkage and strength |
| US9567256B2 (en) | 2013-03-15 | 2017-02-14 | Unifrax I Llc | Inorganic fiber |
| US9708214B2 (en) | 2014-07-16 | 2017-07-18 | Unifrax I Llc | Inorganic fiber with improved shrinkage and strength |
| US9919957B2 (en) | 2016-01-19 | 2018-03-20 | Unifrax I Llc | Inorganic fiber |
| US10023491B2 (en) | 2014-07-16 | 2018-07-17 | Unifrax I Llc | Inorganic fiber |
| US10882779B2 (en) | 2018-05-25 | 2021-01-05 | Unifrax I Llc | Inorganic fiber |
| US11203551B2 (en) | 2017-10-10 | 2021-12-21 | Unifrax I Llc | Low biopersistence inorganic fiber free of crystalline silica |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2008106340A (ja) * | 2006-10-27 | 2008-05-08 | Nhk Spring Co Ltd | 鉄鋼用りん酸アルミニウム系化成処理液及びその作製方法 |
| CN110438485A (zh) * | 2019-07-29 | 2019-11-12 | 吴俊杰 | 一种pvc喷胶工艺的磷化处理系统 |
Family Cites Families (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR884852A (fr) * | 1940-05-10 | 1943-08-30 | Opel Adam Ag | Procédé pour protéger contre la rouille la surface intérieure des réservoirs àessence et des canalisations pour combustibles liquides |
| JPS536945B2 (de) * | 1973-02-27 | 1978-03-13 | ||
| JPS51136539A (en) * | 1975-05-22 | 1976-11-26 | Ota Toshuki | Process for coating aluminum with inorganic substance |
| JPS5481132A (en) * | 1977-12-13 | 1979-06-28 | Teikoku Kako Kk | Steel materials for use in ferroconcretes |
| JPS54148139A (en) * | 1978-04-24 | 1979-11-20 | Nippon Steel Corp | Bolt set excellent in ease to paint, corrosion resistance, lubricativity, and co-turning inhibition |
| US4592958A (en) * | 1983-01-18 | 1986-06-03 | Sermatech | Coated part, coating therefor and method of forming same |
-
1987
- 1987-08-03 JP JP62192591A patent/JPH0730459B2/ja not_active Expired - Lifetime
-
1988
- 1988-08-03 AU AU20386/88A patent/AU606726B2/en not_active Ceased
- 1988-08-03 EP EP88112601A patent/EP0302465A3/de not_active Withdrawn
- 1988-08-03 BR BR8803842A patent/BR8803842A/pt not_active IP Right Cessation
- 1988-08-31 MX MX012534A patent/MX170165B/es unknown
Cited By (27)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0991365A4 (de) * | 1997-04-30 | 2000-04-12 | Medquest Products Inc | Elektrochirurgische klinge mit einem leitenden nicht klebendem überzug |
| DE10014035B4 (de) * | 2000-03-22 | 2006-07-13 | Electro Chemical Engineering Gmbh | Gefärbte Konversionsschicht, eine Lösung zu ihrer Herstellung sowie ihre Verwendung |
| US7678465B2 (en) | 2002-07-24 | 2010-03-16 | Applied Thin Films, Inc. | Aluminum phosphate compounds, compositions, materials and related metal coatings |
| US8124184B2 (en) | 2002-07-24 | 2012-02-28 | Applied Thin Films, Inc. | Aluminum phosphate compounds, compositions, materials and related metal coatings |
| US7682700B2 (en) | 2002-08-14 | 2010-03-23 | Applied Thin Films, Inc. | Aluminum phosphate compounds, compositions, materials and related composites |
| US7311944B2 (en) | 2002-12-23 | 2007-12-25 | Applied Thin Films, Inc. | Aluminum phosphate coatings |
| WO2005061218A1 (en) * | 2003-11-19 | 2005-07-07 | Applied Thin Films, Inc. | Aluminum phosphate compounds, compositions, materials and related metal coatings |
| AU2003304644B2 (en) * | 2003-11-19 | 2010-09-30 | Applied Thin Films, Inc. | Aluminum phosphate compounds, compositions, materials and related metal coatings |
| US7887917B2 (en) | 2005-06-30 | 2011-02-15 | Unifrax I Llc | Inorganic fiber |
| US8551897B2 (en) | 2005-06-30 | 2013-10-08 | Unifrax I Llc | Inorganic fiber |
| EP1743955A2 (de) | 2005-07-15 | 2007-01-17 | NHK Spring Co., Ltd. | Stahlteil mit hervorragendem Korrosionswiderstand und Korrosionsermüdungswiderstand, sowie Oberflächendbehandlung zur Herstellung |
| EP1743955A3 (de) * | 2005-07-15 | 2007-01-24 | NHK Spring Co., Ltd. | Stahlteil mit hervorragendem Korrosionswiderstand und Korrosionsermüdungswiderstand, sowie Oberflächendbehandlung zur Herstellung |
| US8497018B2 (en) | 2010-01-27 | 2013-07-30 | Applied Thin Films, Inc. | High temperature stable amorphous silica-rich aluminosilicates |
| CN103044995A (zh) * | 2013-01-28 | 2013-04-17 | 陈立晓 | 一种柴油机排气管道高温涂料 |
| US9919954B2 (en) | 2013-03-15 | 2018-03-20 | Unifrax I Llc | Inorganic fiber |
| US9567256B2 (en) | 2013-03-15 | 2017-02-14 | Unifrax I Llc | Inorganic fiber |
| CN103741195A (zh) * | 2013-12-23 | 2014-04-23 | 南通恒新金属工艺科技有限公司 | 钢丝电解磷化处理装置 |
| CN103741195B (zh) * | 2013-12-23 | 2016-06-15 | 南通恒新金属工艺科技有限公司 | 钢丝电解磷化处理装置 |
| US10023491B2 (en) | 2014-07-16 | 2018-07-17 | Unifrax I Llc | Inorganic fiber |
| US9708214B2 (en) | 2014-07-16 | 2017-07-18 | Unifrax I Llc | Inorganic fiber with improved shrinkage and strength |
| US10301213B2 (en) | 2014-07-16 | 2019-05-28 | Unifrax I Llc | Inorganic fiber with improved shrinkage and strength |
| US9926224B2 (en) | 2014-07-17 | 2018-03-27 | Unifrax I Llc | Inorganic fiber with improved shrinkage and strength |
| US9556063B2 (en) | 2014-07-17 | 2017-01-31 | Unifrax I Llc | Inorganic fiber with improved shrinkage and strength |
| US9919957B2 (en) | 2016-01-19 | 2018-03-20 | Unifrax I Llc | Inorganic fiber |
| US11203551B2 (en) | 2017-10-10 | 2021-12-21 | Unifrax I Llc | Low biopersistence inorganic fiber free of crystalline silica |
| US12122704B2 (en) | 2017-10-10 | 2024-10-22 | Unifrax I Llc | Low biopersistence inorganic fiber free of crystalline silica |
| US10882779B2 (en) | 2018-05-25 | 2021-01-05 | Unifrax I Llc | Inorganic fiber |
Also Published As
| Publication number | Publication date |
|---|---|
| AU2038688A (en) | 1989-02-09 |
| BR8803842A (pt) | 1989-02-21 |
| AU606726B2 (en) | 1991-02-14 |
| JPS6436774A (en) | 1989-02-07 |
| JPH0730459B2 (ja) | 1995-04-05 |
| EP0302465A3 (de) | 1990-01-31 |
| MX170165B (es) | 1993-08-10 |
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