US3721534A - Method of forming protective coatings on ferrous metal and the resulting article - Google Patents
Method of forming protective coatings on ferrous metal and the resulting article Download PDFInfo
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- US3721534A US3721534A US00177103A US3721534DA US3721534A US 3721534 A US3721534 A US 3721534A US 00177103 A US00177103 A US 00177103A US 3721534D A US3721534D A US 3721534DA US 3721534 A US3721534 A US 3721534A
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- ferrous metal
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- 238000000034 method Methods 0.000 title claims abstract description 16
- CWYNVVGOOAEACU-UHFFFAOYSA-N Fe2+ Chemical compound [Fe+2] CWYNVVGOOAEACU-UHFFFAOYSA-N 0.000 title claims abstract description 13
- 229910052751 metal Inorganic materials 0.000 title claims abstract description 13
- 239000002184 metal Substances 0.000 title claims abstract description 13
- 239000011253 protective coating Substances 0.000 title description 3
- 239000000758 substrate Substances 0.000 claims abstract description 29
- 239000002131 composite material Substances 0.000 claims abstract description 18
- NPXOKRUENSOPAO-UHFFFAOYSA-N Raney nickel Chemical group [Al].[Ni] NPXOKRUENSOPAO-UHFFFAOYSA-N 0.000 claims abstract description 12
- 229910000907 nickel aluminide Inorganic materials 0.000 claims abstract description 12
- 230000008569 process Effects 0.000 claims abstract description 12
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical group O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims abstract description 11
- 238000000151 deposition Methods 0.000 claims abstract description 10
- 239000000463 material Substances 0.000 claims abstract description 9
- 239000011224 oxide ceramic Substances 0.000 claims abstract description 7
- 229910052574 oxide ceramic Inorganic materials 0.000 claims abstract description 7
- 229910000623 nickel–chromium alloy Inorganic materials 0.000 claims abstract description 6
- 239000010410 layer Substances 0.000 claims description 43
- 229910045601 alloy Inorganic materials 0.000 claims description 8
- 239000000956 alloy Substances 0.000 claims description 8
- 238000010438 heat treatment Methods 0.000 claims description 7
- 239000000843 powder Substances 0.000 claims description 7
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 6
- 229910052804 chromium Inorganic materials 0.000 claims description 6
- 239000011651 chromium Substances 0.000 claims description 6
- 229910001018 Cast iron Inorganic materials 0.000 claims description 5
- 229910000975 Carbon steel Inorganic materials 0.000 claims description 4
- 239000000919 ceramic Substances 0.000 claims description 4
- 239000011247 coating layer Substances 0.000 claims description 4
- 238000010285 flame spraying Methods 0.000 claims description 4
- 239000010962 carbon steel Substances 0.000 claims description 2
- 229910052782 aluminium Inorganic materials 0.000 description 11
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 11
- 239000011248 coating agent Substances 0.000 description 7
- 238000000576 coating method Methods 0.000 description 7
- 238000005266 casting Methods 0.000 description 6
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 4
- 238000005488 sandblasting Methods 0.000 description 3
- 229910001220 stainless steel Inorganic materials 0.000 description 3
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 229910052759 nickel Inorganic materials 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 241001387976 Pera Species 0.000 description 1
- 229910001315 Tool steel Inorganic materials 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 125000004122 cyclic group Chemical group 0.000 description 1
- 230000001351 cycling effect Effects 0.000 description 1
- 230000003028 elevating effect Effects 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910001120 nichrome Inorganic materials 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 238000010120 permanent mold casting Methods 0.000 description 1
- 239000003870 refractory metal Substances 0.000 description 1
- 230000003252 repetitive effect Effects 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 235000012239 silicon dioxide Nutrition 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 238000004901 spalling Methods 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000004408 titanium dioxide Substances 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C3/00—Selection of compositions for coating the surfaces of moulds, cores, or patterns
-
- 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
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
-
- 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
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
- C23C4/11—Oxides
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
- Y10T428/12535—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.] with additional, spatially distinct nonmetal component
- Y10T428/12611—Oxide-containing component
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
- Y10T428/12736—Al-base component
- Y10T428/1275—Next to Group VIII or IB metal-base component
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
- Y10T428/12771—Transition metal-base component
- Y10T428/12861—Group VIII or IB metal-base component
- Y10T428/12937—Co- or Ni-base component next to Fe-base component
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
- Y10T428/12771—Transition metal-base component
- Y10T428/12861—Group VIII or IB metal-base component
- Y10T428/12944—Ni-base component
Definitions
- ABSTRACT A composite comprising a ferrous metal substrate and three layers of specific materials is disclosed.
- the first layer is nickel aluminide
- the second layer is a nickelchromium alloy
- the third layer is an aluminum oxide ceramic.
- a process for producing the composite is also disclosed which comprises depositing the layers in a specific order under controlled temperature conditions.
- This invention relates to coated ferrous metalsubstrates. More particularly, it relates to coated materials suitable for the casting of molten aluminum.
- Molds and cores which are useful in the permanent mold casting of various aluminum articles in addition to withstanding the temperatures of molten aluminum have to be insoluble in molten aluminum, have good heat transfer properties and leave a smooth finish to the cast article.
- One of the presently used methods is to use a tool steel coated with a parting compound which enables the cast aluminum article to be separated from the mold, however, after repeated casting, for example, in the order of 600 to 650 castings, the parting compound coating cracks and spans and has to be removed by sandblasting.
- Other materials such as cast iron which are generally less expensive are not suitable since the sandblasting yields an unsmooth finish.
- Refractory metal molds have been used but are difficult to machine, thus adding to the cost of the mold.
- a composite comprising a ferrous metal substrate and a first layer of nickel aluminide metallurgically bonded to the substrate, a second layer of a nickel-chromium alloy mechanically bonded to the first layer and a third layer of an aluminum oxide mechanically bonded to the second layer.
- the substrate is first heated to a specified temperature, depositing by flame spraying a coating of nickel aluminide to the substrate, heating the coating substrate to a specified temperature and depositing a coating of nickel-chromium alloy on said first coating, elevating the temperature of the material containing the first and second layers to a specified temperature, applying an aluminum oxide powder to the second layer and allowing the coated material containing the three layers to slowly cool in air to ambient temperature.
- any ferrous metal such as cast iron, carbon steels, and stainless steels can be used as substrates.
- Suitable substrates include the carbon and stainless steels such as the steels listed in Metals Handbook as 1010, 1020, 1030, 300 and 400 series of stainless steels.
- the first layer which is metallurgically bonded to the substrate is essentially nickel aluminide.
- the substrate is heated to from about 275 F to about 325 F with about 300 F being preferred by flame spraying a nickel aluminide wire onto the heated surface of the substrate.
- a thickness of the first layer of from about 5 to 10 mils is preferred.
- the temperature of the substrate containing the first layer is raised to a temperature of about 400 to 450 F and a second layer of an alloy containing about 19 percent to about 21 percent chromium and balance essentially nickel is applied by spraying an alloy powder onto the heated surface sufficiently to obtain a thickness of from about 5 to about 10 mils.
- Preferred alloys contain from about 19 percent to about 21 percent chromium with about 20 percent being preferred.
- Nichrome is a trade name for such alloys and is supplied by a variety of alloy producers. It is believed that this second layer achieves a well-bonded finished product which can withstand temperature cycling without cracking or spalling. Additionally, it is believed this second layer providesa barrier to the oxidation of the substrate.
- the material After application of the second layer the material is raised to a temperature in excess of 600 F but below about 700 F and aluminum oxide ceramic powder containing from about 93 to about 95 percent by weight of aluminum oxide is deposited.
- Suitable ceramics are well known in the art.
- a typical example is aluminum oxide 94 percent, titanium dioxide 2.5 percent, silicon dioxide 2.0 percent, iron oxide (Fe O 1.0 percent, other oxides balance.
- the thickness of the ceramic layer is from about 1 to about 3 mils. If the third layer is in excess of about 3 mils, there is a tendency of the coating to crack.
- a cast iron substrate coated according to the process of this invention containing a first layer of nickel aluminide of about 5 mils thickness, a second layer of an alloy having 20 percent chromium and about 5 mil thick and a third layer of about 94 percent aluminum oxide ceramic of about 3 mils thickness was used for over 1 1,000 castings without any appreciable change in appearance.
- the composite While described in relationship to use in casting aluminum the composite is not so limited. The invention is useful in any application where the composite is subjected to cyclic temperatures up to about 700 C or where the composite is in contact with molten aluminum.
- a composite comprising a ferrous metal substrate, a first layer metallurgically bonded thereto of nickel aluminide, a second layer bonded to said first layer consisting essentially of from 19 to 21 percent by weight of chromium, balance nickel and a third layer of an aluminum oxide ceramic bonded to said second layer, said third layer less than 3 mils thickness.
- a process comprising a. heating a ferrous metal substrate to a temperature of from about 275 F to about 325 F, b. depositing on said substrate a first coating layer of nickel aluminide by flame spraying nickel aluminide on said layer, c. heating the resulting coated material to a second temperature of from about 400 F to about 450 F, d. depositing on said first coating layer an alloy powder consisting essentially of from about 19 percent to about 21 percent by weight chromium to form a second layer of a nickel-chromium alloy, e. heating said coated substrate having said first and second layers to a third temperature of about 600 F to about 700 F and f. depositing sufficient aluminum oxide ceramic powder on said second layer to form a ceramic layer of about 1 to about 3 mils thickness. 6.
- said first temperature is about 300 F.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Laminated Bodies (AREA)
Abstract
A composite comprising a ferrous metal substrate and three layers of specific materials is disclosed. The first layer is nickel aluminide, the second layer is a nickel-chromium alloy and the third layer is an aluminum oxide ceramic. A process for producing the composite is also disclosed which comprises depositing the layers in a specific order under controlled temperature conditions.
Description
United States Patent [191 Kubick 51March 20, 1973 [54] METHOD OF FORMING PROTECTIVE COATINGS ON FERROUS METAL AND THE RESULTING ARTICLE [75] Inventor: Richard J. Kubick, Queens County,
Beechhurst, N.Y.
[73] Assignee: GTE Sylvania Incorporated, Detroit,
Mich.
22 Filed: Sept. 1,1971
21 Appl.No.: 177,103
[52] US. Cl. ..29/195, 29/1962, 29/1966, 117/69, 117/71 M, ll7/93.l PF, 117/105,
[51] Int. Cl ..B32b 15/00, B32b 15/04 [58] Field of Search ..117/71 M, 69, 93.1 PF, 105, 1l7/l05.2; 29/195, 196.2, 196.6
[56] References Cited UNITED STATES PATENTS 2,823,139 2/1958 Schulze et a1 ..117/71 M 2,903,375 9/1959 Peras ..29/195 X Primary Examiner-Alfred L. Leavitt Assistant Examiner-J. R. Batten, Jr. Attorney-Norman J. OMalley et al.
[57] ABSTRACT A composite comprising a ferrous metal substrate and three layers of specific materials is disclosed. The first layer is nickel aluminide, the second layer is a nickelchromium alloy and the third layer is an aluminum oxide ceramic. A process for producing the composite is also disclosed which comprises depositing the layers in a specific order under controlled temperature conditions.
8 Claims, N0 Drawings METHOD OF FORMING PROTECTIVE COATINGS ON FERROUS METAL AND THE RESULTING ARTICLE BACKGROUND OF THE INVENTION This invention relates to coated ferrous metalsubstrates. More particularly, it relates to coated materials suitable for the casting of molten aluminum.
Molds and cores which are useful in the permanent mold casting of various aluminum articles in addition to withstanding the temperatures of molten aluminum have to be insoluble in molten aluminum, have good heat transfer properties and leave a smooth finish to the cast article. One of the presently used methods is to use a tool steel coated with a parting compound which enables the cast aluminum article to be separated from the mold, however, after repeated casting, for example, in the order of 600 to 650 castings, the parting compound coating cracks and spans and has to be removed by sandblasting. Other materials such as cast iron which are generally less expensive are not suitable since the sandblasting yields an unsmooth finish. Refractory metal molds have been used but are difficult to machine, thus adding to the cost of the mold.
It is believed, therefore, that a composition that can withstand the temperatures of molten aluminum, has good heat transfer p 'operties, does not require expensive steels as a substrate, does not require repetitive sandblasting and allows separation of a smooth cast aluminum article is an advancement in the art.
OBJECTS AND SUMMARY OF THE INVENTION It is an object of this invention to provide a new composite having a ferrous metal substrate that exhibits good heat transfer and is capable of withstanding elevated temperatures.
It is another object of this invention to. provide a composite useful in casting molten aluminum.
It is a further object of this invention to provide a process for producing a composite having a ferrous metal substrate and a coating which is resistant to molten aluminum.
These and other objects are achieved in one embodiment of this invention by providing a composite comprising a ferrous metal substrate and a first layer of nickel aluminide metallurgically bonded to the substrate, a second layer of a nickel-chromium alloy mechanically bonded to the first layer and a third layer of an aluminum oxide mechanically bonded to the second layer.
In another embodiment of this invention the substrate is first heated to a specified temperature, depositing by flame spraying a coating of nickel aluminide to the substrate, heating the coating substrate to a specified temperature and depositing a coating of nickel-chromium alloy on said first coating, elevating the temperature of the material containing the first and second layers to a specified temperature, applying an aluminum oxide powder to the second layer and allowing the coated material containing the three layers to slowly cool in air to ambient temperature.
DESCRIPTION OF THE PREFERRED EMBODIMENTS For a better understanding of the present invention, together with other and further objects, advantages and capabilities thereof, reference is made to the following disclosure and appended claims in connection with the above description of some of the aspects of the invention.
In general, any ferrous metal such as cast iron, carbon steels, and stainless steels can be used as substrates. Suitable substrates include the carbon and stainless steels such as the steels listed in Metals Handbook as 1010, 1020, 1030, 300 and 400 series of stainless steels.
The first layer which is metallurgically bonded to the substrate is essentially nickel aluminide. In the practice of this invention the substrate is heated to from about 275 F to about 325 F with about 300 F being preferred by flame spraying a nickel aluminide wire onto the heated surface of the substrate. A thickness of the first layer of from about 5 to 10 mils is preferred.
The temperature of the substrate containing the first layer is raised to a temperature of about 400 to 450 F and a second layer of an alloy containing about 19 percent to about 21 percent chromium and balance essentially nickel is applied by spraying an alloy powder onto the heated surface sufficiently to obtain a thickness of from about 5 to about 10 mils. Preferred alloys contain from about 19 percent to about 21 percent chromium with about 20 percent being preferred. Nichrome is a trade name for such alloys and is supplied by a variety of alloy producers. It is believed that this second layer achieves a well-bonded finished product which can withstand temperature cycling without cracking or spalling. Additionally, it is believed this second layer providesa barrier to the oxidation of the substrate.
After application of the second layer the material is raised to a temperature in excess of 600 F but below about 700 F and aluminum oxide ceramic powder containing from about 93 to about 95 percent by weight of aluminum oxide is deposited. Suitable ceramics are well known in the art. A typical example is aluminum oxide 94 percent, titanium dioxide 2.5 percent, silicon dioxide 2.0 percent, iron oxide (Fe O 1.0 percent, other oxides balance. The thickness of the ceramic layer is from about 1 to about 3 mils. If the third layer is in excess of about 3 mils, there is a tendency of the coating to crack.
A cast iron substrate coated according to the process of this invention containing a first layer of nickel aluminide of about 5 mils thickness, a second layer of an alloy having 20 percent chromium and about 5 mil thick and a third layer of about 94 percent aluminum oxide ceramic of about 3 mils thickness was used for over 1 1,000 castings without any appreciable change in appearance.
While described in relationship to use in casting aluminum the composite is not so limited. The invention is useful in any application where the composite is subjected to cyclic temperatures up to about 700 C or where the composite is in contact with molten aluminum.
While there has been shown and described what is at present considered the preferred embodiment of the invention, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the scope of the invention as defined by the appended claims.
What is claimed is:
1. A composite comprising a ferrous metal substrate, a first layer metallurgically bonded thereto of nickel aluminide, a second layer bonded to said first layer consisting essentially of from 19 to 21 percent by weight of chromium, balance nickel and a third layer of an aluminum oxide ceramic bonded to said second layer, said third layer less than 3 mils thickness.
2. A composite according to claim 1 wherein said first and second layer have a thickness of from about 5 to about mils.
3. A composite according to claim 2 wherein said substrate is cast iron.
4. A composite according to claim 2 wherein said substrate is carbon steel.
5. A process comprising a. heating a ferrous metal substrate to a temperature of from about 275 F to about 325 F, b. depositing on said substrate a first coating layer of nickel aluminide by flame spraying nickel aluminide on said layer, c. heating the resulting coated material to a second temperature of from about 400 F to about 450 F, d. depositing on said first coating layer an alloy powder consisting essentially of from about 19 percent to about 21 percent by weight chromium to form a second layer of a nickel-chromium alloy, e. heating said coated substrate having said first and second layers to a third temperature of about 600 F to about 700 F and f. depositing sufficient aluminum oxide ceramic powder on said second layer to form a ceramic layer of about 1 to about 3 mils thickness. 6. A process according to claim 5 wherein said first temperature is about 300 F.
7. A process according to claim 6 wherein said second temperature is about 400 F.
- 8. A process according to claim 7 wherein said third temperature is about 600 F.
Claims (7)
- 2. A composite according to claim 1 wherein said first and second layer have a thickness of from about 5 to about 10 mils.
- 3. A composite according to claim 2 wherein said substrate is cast iron.
- 4. A composite according to claim 2 wherein said substrate is carbon steel.
- 5. A process comprising a. heating a ferrous metal substrate to a temperature of from about 275* F to about 325* F, b. depositing on said substrate a first coating layer of nickel aluminide by flame spraying nickel aluminide on said layer, c. heating the resulting coated material to a second temperature of from about 400* F to about 450* F, d. depositing on said first coating layer an alloy powder consisting essentially of from about 19 percent to about 21 percent by weight chromium to form a second layer of a nickel-chromium alloy, e. heating said coated substrate having said first and second layers to a third temperature of about 600* F to about 700* F and f. depositing sufficient aluminum oxide ceramic powder on said second layer to form a ceramic layer of about 1 to about 3 mils thickness.
- 6. A process according to claim 5 wherein said first temperature is about 300* F.
- 7. A process according to claim 6 wherein said second temperature is about 400* F.
- 8. A process according to claim 7 wherein said third temperature is about 600* F.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US17710371A | 1971-09-01 | 1971-09-01 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| US3721534A true US3721534A (en) | 1973-03-20 |
Family
ID=22647206
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US00177103A Expired - Lifetime US3721534A (en) | 1971-09-01 | 1971-09-01 | Method of forming protective coatings on ferrous metal and the resulting article |
Country Status (1)
| Country | Link |
|---|---|
| US (1) | US3721534A (en) |
Cited By (21)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3887731A (en) * | 1973-04-23 | 1975-06-03 | Chromalloy American Corp | Corrosion resistant coating system for ferrous metal articles having brazed joints |
| US4017238A (en) * | 1975-04-21 | 1977-04-12 | American Optical Corporation | Mold for casting contact lenses utilizing and electron beam to polymerize the resin lens |
| DE2740398A1 (en) * | 1976-09-09 | 1978-03-16 | Union Carbide Corp | DOUBLE COVER FOR PROTECTION AGAINST THERMAL STRESS AND CORROSION |
| US4298053A (en) * | 1974-03-18 | 1981-11-03 | Metallurgie Hoboken-Overpelt | Casting belts for machines for the continuous casting of metals |
| FR2518123A1 (en) * | 1981-12-14 | 1983-06-17 | United Technologies Corp | PROCESS FOR APPLYING A COATING OF CERAMIC MATERIAL ON A METALLIC SUBSTRATE AND ARTICLE OBTAINED |
| US4639399A (en) * | 1985-11-26 | 1987-01-27 | The United States Of America As Represented By The Secretary Of The Navy | Nickel oxide, ceramic insulated, high temperature coating |
| US4678692A (en) * | 1985-04-29 | 1987-07-07 | Julian Porter | Multilayer protection system |
| US4726368A (en) * | 1985-02-19 | 1988-02-23 | Bioquantum Technologies, Inc. | Non-reflective surgical instruments |
| USRE33876E (en) * | 1975-09-11 | 1992-04-07 | United Technologies Corporation | Thermal barrier coating for nickel and cobalt base super alloys |
| US5523166A (en) * | 1990-05-30 | 1996-06-04 | Nippon Steel Corporation | Process for forming thin film having excellent insulating property and metallic substrate coated with insulating material formed by said process |
| US20110059323A1 (en) * | 2008-03-04 | 2011-03-10 | Friedhelm Schmitz | Alloy, high-temperature corrosion protection layer and layer system |
| US10160162B2 (en) * | 2013-04-10 | 2018-12-25 | Tetra Laval Holdings & Finance S.A. | Induction sealing device and method for manufacturing an induction sealing device |
| US10899082B2 (en) | 2017-07-17 | 2021-01-26 | Tetra Laval Holdings & Finance S.A. | Inductor coil for induction welding of a packaging material |
| US10994495B2 (en) | 2015-11-27 | 2021-05-04 | Tetra Laval Holdings & Finance S.A. | Sealing device with increased robustness |
| US11370571B2 (en) | 2017-07-18 | 2022-06-28 | Tetra Laval Holdings & Finance S.A. | Induction sealing device |
| US11534985B2 (en) | 2016-05-02 | 2022-12-27 | Tetra Laval Holdings & Finance S.A. | Induction sealing system |
| US11548238B2 (en) | 2018-09-10 | 2023-01-10 | Tetra Laval Holdings & Finance S.A. | Method for forming a tube and a method and a packaging machine for forming a package |
| US11554555B2 (en) | 2017-05-30 | 2023-01-17 | Tetra Laval Holdings & Finance S.A. | Apparatus for sealing the top of a package for a food product and system for forming and filling a food package |
| US11820540B2 (en) | 2018-09-11 | 2023-11-21 | Tetra Laval Holdings & Finance S.A. | Packaging apparatus for forming sealed packages |
| US12122547B2 (en) | 2019-02-05 | 2024-10-22 | Tetra Laval Holdings & Finance S.A. | Induction heat sealing device and a method for transversally seal a tube of packaging material |
| US12522394B2 (en) | 2021-02-15 | 2026-01-13 | Tetra Laval Holdings & Finance S.A. | Method for assessing quality of a transversal sealing of a food package |
-
1971
- 1971-09-01 US US00177103A patent/US3721534A/en not_active Expired - Lifetime
Cited By (22)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3887731A (en) * | 1973-04-23 | 1975-06-03 | Chromalloy American Corp | Corrosion resistant coating system for ferrous metal articles having brazed joints |
| US4298053A (en) * | 1974-03-18 | 1981-11-03 | Metallurgie Hoboken-Overpelt | Casting belts for machines for the continuous casting of metals |
| US4017238A (en) * | 1975-04-21 | 1977-04-12 | American Optical Corporation | Mold for casting contact lenses utilizing and electron beam to polymerize the resin lens |
| USRE33876E (en) * | 1975-09-11 | 1992-04-07 | United Technologies Corporation | Thermal barrier coating for nickel and cobalt base super alloys |
| DE2740398A1 (en) * | 1976-09-09 | 1978-03-16 | Union Carbide Corp | DOUBLE COVER FOR PROTECTION AGAINST THERMAL STRESS AND CORROSION |
| FR2518123A1 (en) * | 1981-12-14 | 1983-06-17 | United Technologies Corp | PROCESS FOR APPLYING A COATING OF CERAMIC MATERIAL ON A METALLIC SUBSTRATE AND ARTICLE OBTAINED |
| US4726368A (en) * | 1985-02-19 | 1988-02-23 | Bioquantum Technologies, Inc. | Non-reflective surgical instruments |
| US4678692A (en) * | 1985-04-29 | 1987-07-07 | Julian Porter | Multilayer protection system |
| US4639399A (en) * | 1985-11-26 | 1987-01-27 | The United States Of America As Represented By The Secretary Of The Navy | Nickel oxide, ceramic insulated, high temperature coating |
| US5523166A (en) * | 1990-05-30 | 1996-06-04 | Nippon Steel Corporation | Process for forming thin film having excellent insulating property and metallic substrate coated with insulating material formed by said process |
| US20110059323A1 (en) * | 2008-03-04 | 2011-03-10 | Friedhelm Schmitz | Alloy, high-temperature corrosion protection layer and layer system |
| US10160162B2 (en) * | 2013-04-10 | 2018-12-25 | Tetra Laval Holdings & Finance S.A. | Induction sealing device and method for manufacturing an induction sealing device |
| US10994495B2 (en) | 2015-11-27 | 2021-05-04 | Tetra Laval Holdings & Finance S.A. | Sealing device with increased robustness |
| US11534985B2 (en) | 2016-05-02 | 2022-12-27 | Tetra Laval Holdings & Finance S.A. | Induction sealing system |
| US11554555B2 (en) | 2017-05-30 | 2023-01-17 | Tetra Laval Holdings & Finance S.A. | Apparatus for sealing the top of a package for a food product and system for forming and filling a food package |
| US10899082B2 (en) | 2017-07-17 | 2021-01-26 | Tetra Laval Holdings & Finance S.A. | Inductor coil for induction welding of a packaging material |
| US11370571B2 (en) | 2017-07-18 | 2022-06-28 | Tetra Laval Holdings & Finance S.A. | Induction sealing device |
| US11548238B2 (en) | 2018-09-10 | 2023-01-10 | Tetra Laval Holdings & Finance S.A. | Method for forming a tube and a method and a packaging machine for forming a package |
| US11820540B2 (en) | 2018-09-11 | 2023-11-21 | Tetra Laval Holdings & Finance S.A. | Packaging apparatus for forming sealed packages |
| US12122547B2 (en) | 2019-02-05 | 2024-10-22 | Tetra Laval Holdings & Finance S.A. | Induction heat sealing device and a method for transversally seal a tube of packaging material |
| US12240643B2 (en) | 2019-02-05 | 2025-03-04 | Tetra Laval Holdings & Finance S.A. | Induction heat sealing device and a method for transversally seal a tube of packaging material |
| US12522394B2 (en) | 2021-02-15 | 2026-01-13 | Tetra Laval Holdings & Finance S.A. | Method for assessing quality of a transversal sealing of a food package |
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