EP3719181A2 - Procédé de fabrication d'une couche d'oxyde thermiquement relaxée et couche d'oxyde - Google Patents
Procédé de fabrication d'une couche d'oxyde thermiquement relaxée et couche d'oxyde Download PDFInfo
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- EP3719181A2 EP3719181A2 EP20168188.9A EP20168188A EP3719181A2 EP 3719181 A2 EP3719181 A2 EP 3719181A2 EP 20168188 A EP20168188 A EP 20168188A EP 3719181 A2 EP3719181 A2 EP 3719181A2
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- energy
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- oxidation process
- oxide layer
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Images
Classifications
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- 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
- C25D11/02—Anodisation
- C25D11/026—Anodisation with spark discharge
-
- 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
- C25D11/02—Anodisation
- C25D11/024—Anodisation under pulsed or modulated current or potential
-
- 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
- C25D11/02—Anodisation
- C25D11/30—Anodisation of magnesium or alloys based thereon
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D21/00—Processes for servicing or operating cells for electrolytic coating
- C25D21/12—Process control or regulation
-
- 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
- C25D11/02—Anodisation
- C25D11/04—Anodisation of aluminium or alloys based thereon
- C25D11/06—Anodisation of aluminium or alloys based thereon characterised by the electrolytes used
- C25D11/08—Anodisation of aluminium or alloys based thereon characterised by the electrolytes used containing inorganic acids
Definitions
- the invention is based on a method for producing a thermally relaxed oxide layer and an oxide layer produced by means of this method.
- the present invention relates to a method for producing an oxidic, in a special form an ultra-fine ceramic coating on the surface of light metals by means of phase-specific, thermally relaxed oxide layers (PTO).
- PTO phase-specific, thermally relaxed oxide layers
- the present invention relates to a thermoelectrochemical (thermo-optical or acoustic), preferably multifunctional, pulse management for phase-specific, thermally relaxed oxide layers, in particular on valve metals.
- Hydrated oxide layers can be produced on light metal surfaces by means of anodic polarization.
- the layers are created via a barrier layer on the surface to be coated, in which the base material is oxidized in the usually acidic electrolyte.
- Hard, ceramic layers can be produced by means of PEO (plasma electrolytic oxidation processes) due to transformations on a light metal surface.
- the layers are created by spark discharge, i.e. not discharge-free as according to the invention, on the surface to be coated, in which the base material but also reaction products of the electrolyte are melted, which can result in a crystalline or partially crystalline ceramic surface.
- the DE 10 2016 201 951 A1 relates to the coating of hybrid components.
- Paragraphs 18 and 19, in particular, show that different current and voltage amplitudes are not modulated, but rather that they are combined in series.
- the object of the invention is therefore to provide a method for producing an oxide layer and an oxide layer produced by means of this method, by means of which the disadvantages of the prior art are overcome.
- the method according to the invention for producing an oxide layer with the features of claim 1 have the advantage that in the method according to the invention for producing an oxide layer on a surface of a material by means of an electrolytic oxidation process, the energy required for the oxidation process is required, is supplied in pulses, wherein an energy pulse can consist of three phases, namely the initial phase, middle phase and end phase, and, preferably at least in the middle phase, i.e. in the region of an energy maximum of an energy pulse, the oxidation process is discharge-free, i.e. free from spontaneous and / or uncontrolled discharge takes place, preferably essentially free of discharge, and as a result thereof takes place in a thermally relaxed manner.
- thermally relaxed can mean that the oxidation process takes place without or with only a few temperature peaks due to (uncontrolled) discharge between the workpiece and the electrode.
- the discharge-free oxidation according to the invention can be free from uncontrolled lightning discharge.
- No discharge can in particular refer to a spontaneous and / or uncontrolled discharge, in particular a lightning discharge.
- a lightning discharge can in particular have optical / visual effects and / or an arc / lightning flashover between the workpiece to be coated and the electrode.
- a discharge-free oxidation process can therefore be free of optical / visual effects and / or an electric arc / flashover between the workpiece to be coated and the electrode.
- the amount of energy / voltage provided for the coating can thus be provided below the, preferably visual, spark formation (between workpiece and electrode) during the electrolytic oxidation process.
- this first / initial oxide layer a further formation of the oxide layer, in particular until the final, desired layer thickness is reached, can take place without discharge in this sense.
- This requirement can be material-specific.
- the layer thickness formed over time can be determined both in-situ and ex-situ (preliminary tests).
- the layer thickness and / or quality can thus be set particularly reliably via the coating duration and applied voltage / energy (in particular via its modulation).
- a particularly low energy / voltage can favor a particularly low porosity.
- the voltage / energy actually to be applied can be highly dependent on the material, which is why a suitable voltage / energy for a (essentially) discharge-free coating process can be determined, for example, by preliminary tests for the respective coating.
- the ceramic layers produced in this way serve to protect light metal surfaces against wear and corrosion.
- the energy supply can be regulated and / or modulated separately in each phase.
- the middle phase can be short or long, but it can also approach zero, so that the energy pulse then practically only consists of the initial phase and an end phase.
- the material is a metal.
- This can be a light metal or a valve metal, for example.
- a coating ie the oxidation process, takes place (visually / optically) without discharge, but at least essentially without discharge, even during the initial phase and / or in the end phase of an energy pulse.
- the occurrence of discharges on the surface to be coated can cause local overheating of the material, which can promote uncontrolled growth of the oxide layer.
- This uncontrolled growth which can take place in the form of microvolcanoes on the surface of the workpiece to be coated, favors unfavorable pore formation in the oxide layer.
- All common Al, Mg, Ti, wrought and cast alloys can be coated with the method according to the invention. It can also be used to coat components with complex geometry and / or large areas (> 1 m 2 ), preferably 8 m 2 . Of course, it can also be used to coat components with areas ⁇ 1 m 2 .
- a plurality of energy pulses are supplied, of which at least one pulse, preferably a plurality or all pulses, in particular in its middle phase, is / are modulated (deviation from a sinusoidal curve and / or shape, which can be designed as a half trapezoid and / or disruptive digital shape and / or modulation of the maximum energy of a pulse compared to a others).
- the individual energy pulses are preferably modulated as required. This modulation can be based on a feedback with a sensor-based monitoring of the resulting oxide layer and / or its temperature. If, for example, too high a temperature is detected on the workpiece, which can be seen as an indication of an impending discharge, modulation, especially in the middle phase of an energy pulse, can be used to adapt it to lower the temperature of the workpiece.
- a disturbance of the (regular) shape of the pulse can be controlled, which is a half trapezoid and / or disruptive (e.g. disturbed) digital form (e.g. Figures 2a to 3b ) can be designed to be provided.
- This disturbance can take place, for example, in the form of one or more local maxima, in particular in the area of the middle phase.
- the modulation can accordingly provide an energy pulse with more than one (local) maximum.
- These local maxima can differ from 2 individual pulses in that the local minimum between them does not correspond to the global minimum (energy in the range of approximately 0 or less than 20%).
- the local minimum or the multiple local minima can be 0.1% to 10% below the individual local maxima.
- a local minimum can thus preferably have an amount equal to 90% to 99.9% of the maximum energy of an energy pulse.
- modulation of an energy pulse can prevent a discharge, in particular a discharge flash, between the workpiece and the electrode during the oxidation process. This can be possible even if the energy of the Energy pulse or a corresponding applied voltage would be sufficient in terms of height to provoke a discharge on the workpiece.
- a necessary energy range can be a material-dependent activation / or start-up energy for the oxidation process, which is supplemented by additional energy (or voltage) modulated onto the basic form of the energy pulse / voltage pulse.
- the modulated additional (also negative) energy / extra voltage can preferably be in the single-digit percentage range of the actual energy pulse / voltage pulse. It is particularly preferably below 15% of the actual energy pulse.
- the energy supply is varied via voltage and / or current density.
- the voltage can be kept constant and the current density can be regulated or vice versa.
- the voltage and the current density could also be varied at the same time.
- At least two, preferably a plurality, are individually modulated, that is to say differ in their modulation and / or maximum energy.
- a modulation of the energy or the voltage can take place on individual pulses or groups of pulses as required.
- the modulations of the individual pulses can be distinguishable from one another, that is, they can have different values.
- At least one energy pulse has anodic, cathodic and / or bipolar polarization.
- the energy for the oxidation process corresponds to an applied voltage and / or an energy pulse to a voltage amplitude with a corresponding initial phase, middle phase and end phase.
- An energy pulse can thus correspond to a voltage pulse of a corresponding amplitude (energy).
- a modulation can correspond to a superposition of at least two energy pulses or voltage amplitudes. 2, 3 or up to 5 superimpositions are particularly preferably conceivable for modulation according to the method according to the invention.
- At least one energy pulse has an asymmetrical signal shape.
- At least one energy pulse has a rising edge in the initial phase and a falling edge in the end phase, the rising edge of the energy pulse having a different slope than the falling edge of the energy pulse or at least one energy pulse having a a rising edge in the initial phase and a rising edge in the end phase, the falling edge of the energy pulse having a different slope than the rising edge of the energy pulse.
- At least two energy pulses have identical signal shapes.
- it is z. B. act around two or more successive energy pulses.
- a periodic repetition of the energy pulses with an identical signal form is also conceivable.
- At least two energy pulses have different signal shapes. It can be, for. B. act around two or more successive energy pulses. A periodic repetition of the energy pulses, which have a different signal shape, is also conceivable.
- At least two energy pulses have signal shapes that are symmetrical to one another. It can be, for. B. are two or more successive energy pulses, the signal shape is reflected, for example, in each case on a mirror axis or a mirror point. A periodic repetition of the energy pulses, which have a mutually symmetrical signal form, is also conceivable.
- the energy supply and / or the growth of the oxide layer is monitored by means of at least one sensor during the oxidation process. This enables precise monitoring of the entire oxidation process.
- the at least one sensor is an optical sensor, an acoustic sensor or a temperature sensor.
- a combination of different sensors is of course also conceivable.
- the energy supply during the oxidation process is dependent on at least one measured value obtained by means of the at least one sensor is determined varies. Automation of the oxidation process is conceivable as a result, the energy supply being controlled arbitrarily and as a function of the measured value.
- At least one further energy signal is modulated onto at least one energy pulse, at least in phases.
- arbitrary peaks can be modulated onto the signal shape.
- the entire energy pulse as well as the beginning, middle and end phases can be modulated separately or in combination.
- the oxide layer according to the invention produced by a method according to one of claims 1 to 13, consisting of a barrier layer arranged on a surface of a material, an inner layer arranged on the barrier layer and an outer layer arranged on the inner layer, has the advantage that the oxide layer has a total layer thickness of 0.5 - 500 ⁇ m.
- the barrier layer has a thickness of up to 2 ⁇ m.
- the outer layer has a maximum of 10% of the total layer thickness.
- the process presented can also be applied to a wide variety of wrought and cast alloys of aluminum, magnesium and titanium and leads to layers that are efficient, thin and smooth and ensure a homogeneous morphology.
- the method presented is also suitable for generating oxide-hydrated layers. Hydrated oxide layers can be applied by means of anodic polarization Light metal surfaces are generated. In this case, the layers are created via a barrier layer on the surface to be coated, in which the base material is oxidized in the usually acidic electrolyte.
- the invention (innovation) described below represents a significant improvement in the corrosion resistance.
- the main, innovatively implemented idea is the targeted energy supply and precise energy deposition at the reaction site of the metal / metal oxide phase boundary.
- the phase-specific, thermally relaxed (thermo-relaxed) oxide layer formation takes place with the alloy and layer-specific, precisely adapted energy dose and reaction speed (dynamics of the reaction) that correspond to the process maturity.
- the targeted control of the conversion of, for example, the hydrated oxide form into the ceramic oxide forms is an essential part of the invention. There is preferably no direct reaction between the metal and the oxygen present.
- the fast and dynamic process is monitored and regulated in situ through highly efficient, innovative monitoring.
- At least one RDCZ reference detector controller cell
- the RDCZ depicts the cell in which the coating process takes place.
- the same flow velocity of the electrolyte as the same sample alloy for example Al, Mg or Ti
- the batch actually to be refined can be controlled via the coupled MSR (measurement control rule) module (see Fig. 1 ).
- the technique described here can be used to form oxide and / or ceramic layers on light metals.
- the process is suitable for a large number of electrolytes. There are no restrictions on the pH value or the substances contained. Acid and alkaline electrolytes lead to significantly improved layers with this control. In particular, the benefits of this invention can be observed at low concentration. At these concentrations, particularly high energy densities and corresponding current densities (significantly greater than 10A / dm 2 ) can be used helpful for the targeted PTO.
- the environmentally friendly low substance concentrations in the electrolyte enable a broader energy band for the process.
- An electrolyte could contain 1-4 g / l alkali metal hydroxide and up to 15 g / l silicate. The presence of alkali pyrophosphate at up to 20g / l has also been shown to be helpful.
- the layers can be specifically controlled in terms of density (defective secondary reactions such as exothermic electrochemical conversion of intermetallic phases are suppressed) and phases.
- dense secondary reactions such as exothermic electrochemical conversion of intermetallic phases are suppressed
- phases With the very low energy densities ( ⁇ 10 A / dm 2 ) primarily oxide hydrate layers are formed, with the high energy densities ( ⁇ 10 A / dm 2 ), for example, the ⁇ - and ⁇ - Al 2 O 3 phases can be enriched in a targeted manner in aluminum substrates.
- the form of the arbitrary signal on the one hand and the polarization of the signal as a whole are used specifically for this purpose.
- Frequency 0.1Hz to 8kHz, preferably 3k Hz Frequency for repetition should be 3200 Hz Rise time of the signal ...% of the total signal Fall time of the signal ..% of the total signal Base polarization of the signal In% of the signal height up to 80%, preferably 20% Signal on the signal in + -% of the total signal height +/- 60% preferably +/- 25%
- Fig. 1 shows a highly efficient, innovative monitoring (optical, acoustic and temperature sensors), which enables fast and dynamic process control and regulation: RDCZ, which is an option, but not a permanent necessity, as a preferred control after the creation of the process parameters, with light sensor Lab (color and brightness of the events are measured, IR camera (thermal evaluation), microphone (acoustic evaluation - volume, harmonic oscillations, harmonics), the same electrolyte (bypass) and the same flow rate as the batch.
- Fig. 3 shows a picture of the hydrated oxide surface, the left part of the picture a) showing a surface of a hydrated oxide surface as it is currently available on the market, and the right part of the picture b) showing the above-described, produced by the PTO process, the hydrated oxide surface.
- electrochemical impedance measurements of layers produced by PTO on different substrates were carried out for the following examples.
- the measurements were carried out in a 0.1M NaCl solution using an Ag / Ag-Cl reference electrode and a platinum-plated titanium counter electrode. Measurements were made with an amplitude of 10 mV in the frequency range of 10 2 -10 6 Hz around the free corrosion potential.
- Fig. 4 shows the basic structure of a ceramic layer.
- the overall layer consists of a thin barrier layer arranged on the substrate, a dense ceramic inner layer and an outer, porous layer.
- Fig. 5 shows the model with which the measurement data were fitted (model for simulating the EIS results of the PTO shift systems).
- Rs stands for the electrolyte resistance.
- the entire layer is divided into a porous outer layer (pore) and a compactly closed inner layer (inner).
- the CPE is a "constant phase element" that maps the capacity of a layer that has pores and / or unevenness.
- R stands for the resistance of the layer components.
- Example 2 shows the ceramization of the aluminum alloy 6082 (AlMgSi1) using the new, innovative process described here.
- This sample 6082 PTO was produced with the energy regime (signal 3a - high-resolution fully arbitrary phase-reactive bipolar signal) in an electrolyte with the following composition: 3g / l alkali hydroxide and 10g / l alkali silicate as well as 10 g / l alkali pyrophosphate.
- the total duration is 7 minutes and leads to a layer thickness of 38 ⁇ m.
- Fig. 6 shows the fitting results of the EIS measurements of PEO layers on AI EW6082 (fitting results of the PTO layers on AI EW6082: left: layer produced in the novel PTO process, SoA: state-of-the-art process (here a typical Square-wave signal applied, as is currently common in publications and on the market (Aliramezani et al. 2017)), right: Literature values of the existing layer systems (Ref. 4 (Barik et al. 2005), Ref. 5 (Liang 2013)) and Fig.
- Example 3 are PTO layers on the magnesium alloys AZ31, E-Form and AM50.
- the ceramization using the new innovative PTO process described here was also produced in an alkaline electrolyte containing the components alkali hydroxide and alkali silicate as well as alkali pyrophosphate.
- the total duration is 4 minutes and leads to a layer thickness of 27 ⁇ m.
- the energy regime (signal 2a2) was applied to these samples.
- Fig. 8 shows the results of the electrochemical impedance measurement of layers produced by PTO on different magnesium alloys (EIS results of PTO layers on different Mg alloys).
- Fig. 9 shows the fitting results of the EIS measurements in comparison with corresponding literature values (fitting results of the PTO layers on Mg substrates: left: layers produced in the novel PTO process; right: literature values of the existing layer systems (Ref. 1 (Lu et al. 2013)) , Ref. 2 (Lu et al. 2015), Ref 3 (Luca Pezzato 2015))
- R sum total resistance
- the figure includes the capacitances of the two layer sections. The capacities show low values overall, which also suggests that little to no diffusion takes place, which is related to the morphology corresponds to the layers produced, which have a low roughness and only very small pores.
- Fig. 10 shows possible pulse shapes known from the prior art for producing ceramic layers on aluminum.
- the distinction to the novel PTO layers is that in the novel PTO process, pulse signals rise significantly more slowly (rising A) and decay faster than, for example, in the figure above (rapidly falling E).
- the peaks to be observed in the prior art when the pulse is switched on are involuntary system events and not, as in the PTO process, targeted on-top-peak modulations.
- Fig. 11 shows a possible voltage signal for producing PEO layers on titanium as prior art.
- the demarcation from the generation of the new PTO layers can be made with the vertical rise of the voltage signal.
- the layers produced in the novel PTO process show excellent tribological properties. This is shown below using the example of thin PTO layers (10 ⁇ m) on the magnesium alloy E-shape:
- the tribological test was carried out in a pin-on-disc test, a 100Cr6 ball ( ⁇ 6 mm) being used as the static partner.
- the PTO-coated samples were moved in an oscillating manner over a distance of 2.5 mm with a frequency of 0.6 Hz and a normal force of 4N. After a total distance of 80 m, the samples were analyzed.
- Fig. 12 shows the course of the coefficient of friction.
- the coefficient of friction remains very stable in both cases.
- the figure also clearly shows that the layer produced in the 3a process leads to a lower coefficient of friction.
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