CN1847452A - 镍涂覆 - Google Patents

镍涂覆 Download PDF

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CN1847452A
CN1847452A CNA2006100740849A CN200610074084A CN1847452A CN 1847452 A CN1847452 A CN 1847452A CN A2006100740849 A CNA2006100740849 A CN A2006100740849A CN 200610074084 A CN200610074084 A CN 200610074084A CN 1847452 A CN1847452 A CN 1847452A
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T·R·汉龙
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Raytheon Technologies Corp
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Abstract

Ni基的第一材料通过非电镀沉积到基质上。Zn基的第二材料沉积到第一材料上。第一和第二材料中的至少一种材料的一种或多种成分扩散到其它当中。扩散形成了ZnNi合金层，提高了抗腐蚀性。

Description

镍涂覆
技术领域
本发明涉及镍涂层。更具体的说，本发明涉及非电镍硼镀覆。
背景技术
美国专利6,756,134，其公开内容中详尽阐明的部分在此引入作为参考，公开了用于防止腐蚀和受热的锌扩散镍合金涂层。镍和锌层连续的在基质上电镀，然后热扩散。
不同的是，非电镍(EN)涂层已经被用于磨损和腐蚀保护的目的。非电镍磷(ENP或e-NiP)镀覆可以使用次磷酸钠作为还原剂来实现。非电镍硼(ENB或e-NiB)镀覆可以使用化合物，如硼氢化钠或二甲基氨基硼烷作为还原剂来实现。E-NiB涂层可以具有相对于e-NiP涂层抗磨损的优点，但不能提供具有优势的抗腐蚀性能。
发明内容
将镍基第一材料通过电镀施涂到基质上。锌基第二材料通过电镀被施涂到第一材料上。第一和第二材料中的至少一种材料的一种或多种成分扩散到其它当中。这会产生ZnNi合金层，提高抗腐蚀性。
本发明的一个或多个实施例的具体内容结合附图和以下的描述给出。本发明的其它特性、目的和优点从描述、附图和权利要求中可以明显看出。
附图说明
图1是示例涂覆过程的流程图表。
图2是Fe基质上Zn在e-NiB涂层上的双层在扩散前横截面的电子微探针扫描。
图3是图2涂层的放大图。
图4是图3的涂层在热诱导下涂覆层扩散后的图像。
图5是图4的涂层的锌x-光图片。
图6是图4的涂层的镍x-光图片。
图7是图3的涂层的行扫描，给出了Ni，B和Zn含量。
不同附图中相同的参考数字和标记代表相同的要素。
具体实施方式
e-NiB涂层的抗腐蚀性问题被认为是微孔、柱状结构造成的。为了提高抗腐蚀性，人们设想(postulated)在涂覆e-NiB层基质的表面通过电镀、匀浆填充或其它方法施涂锌层，然后与NiB层相互扩散。
在图1中给出的说明过程中，可以形成基质。典型的基质为基于钛的(例如，钛或钛合金)，通过锻造和/或机械加工形成。典型基质被部分用在航空工业中(例如，气体涡轮发动机压缩机叶片、桨叶和其它组件)。在任何清洁或其它处理后，将Ni基第一材料施涂到基质上。可以直接在上面施涂，或施涂一个或多个介入层(intervening layer)。该涂覆可以在第一位置为第一厚度。在基质表面的大部分形成基本均匀的第一厚度。第一厚度可以实际上小于本地基质厚度。典型的第一厚度为至少5μm(例如，10-1000μm)。该厚度依赖于使用目的。对于空间填充(例如，空间修复)，500μm到超过1000μm的厚度是合适的。对于抗磨损和腐蚀，10-100μm可能就足够了。对于仅防止腐蚀，更薄的覆层也是可能的。第一材料可以是NiB，当涂覆时，可以包括1-15％B，更窄一些1-10％。1-5％对于低中B涂覆是合适的，和/或对于高B涂覆，9-14％是合适的。
在任何清洁和/或其它处理后，Zn基第二材料施涂在第一材料上。所述施涂可以，优选直接施涂到上面，或施涂一个或多个介入层(如果这个中间层具有充分的渗透性或扩散性允许在第一和第二材料之间扩散)。可以以第二厚度在第一位置施涂。在基层表面大部分具有基本均匀的第二厚度。第二厚度可以小于第一厚度。典型的第二厚度为2-50μm，更窄为5-20μm。
在任何清洁和/或其它处理后，包括可能的施涂一层或多层附加层，在适当的温度加热，使第一和/或第二材料中的至少一种材料的一种或多种成分扩散到其它当中。这种扩散可以产生ZnNi合金层。加热可以在环境气氛中或惰性气氛中操作。真空或反应性气氛也是可能的。典型加热是在温度至少为300℃时持续至少半小时，更特殊的为300-500℃持续0.5-3小时。扩散可以有效的提供至少与通过加热到450℃的温度持续1.5小时或在300℃的温度持续两小时所达到的扩散同样高的扩散程度。
扩散处理可以形成在所述第二厚度的至少50％深度中基本上10-25％Ni的外层/外侧/上部区域。所述深度可以是所述第二厚度的100-200％，并且可以跨于第一和第二材料的原始连接处/边界。更广泛的，在该区域，Zn含量可以至少为50％，Ni含量可以至少为10％。Zn含量可以至少为70％。
在浅的过渡区域的内部/以下，可以有基本上未改变的第一材料的区域。对于NiB材料，这个基础区域的Ni含量可以至少为50％，B含量至少为1％。典型的厚度至少为10μm，尽管向上该值可以很大。对于中高B材料，Ni含量可以至少为80％，B含量至少为5％。可能有一些B扩散，但是在扩散区域该含量可以比基础区域小很多(例如，小于五分之一)。
可以有进一步的扩散后施涂或处理。如果在升高的温度下操作，扩散可能会重叠。例如，Cr基第三材料可以在至少大部分扩散完成之后或也可以在之前施涂。在扩散后施涂的典型终涂层为基于Cr-VI的，或更优选基于Cr-III的转化涂层，用来进一步改善扩散材料的抗腐蚀性能。
在测试实施例中，只施涂第一和第二材料，然后扩散，并没有另外的处理。图2和图3给出了钢测试基质20，该层在施涂e-NiB涂层22之后，接着电镀锌涂层24。典型NiB涂层基本上由镍和硼组成，并且非常富含硼，硼含量大约为10％(除另外说明，所有百分比为重量百分比)。典型涂层22的厚度为约240μm。典型锌涂层24为电镀锌。典型涂层24的厚度为约10μm。
为引起扩散，典型的基层在空气烘箱中于850(454℃)放置2小时。相互扩散层如图4所示。原始NiB/Zn界面可以看到是贯穿在较浅颜色层的暗线，暗点分布在整个浅颜色层中。界面看上去与图5和图6的X光图类似。
图7给出了线扫描数据，表明Zn扩散到e-NiB层约4μm，Ni而不是B向Zn层以外扩散，结果形成了基本上含Ni重量约为恒定18％的ZnNi合金。由于在该部分外表面中或附近(例如，如果有涂覆层进一步被涂覆)有一定的Zn(作为ZnNi合金)，改善了抗腐蚀性。中间过渡区域相对较薄。总浓度看起来不是100％是由于考虑到采样和使用了未标准化的原始数据。
施涂一方面包括已经存在的e-NiB涂层，另一方面包括电镀扩散的Ni/Zn涂层(例如，美国专利6,756,134)。相对于后者，本处e-NiB涂层的使用可以提供比用标准电镀方法获得的涂层更坚硬的和更高类似于镍层的优点。
本发明的一个或多个实施方式已经描述了。然而，应当理解在不脱离本发明精神和范围的情况下可以进行多种修改。例如，部分操作调节条件影响任一特定操作。多种物品可以使用涂层，多种基层材料可以被使用。这些材料包括金属(例如，Ti-，Fe-和Al基材料)和非金属材料(例如，塑料和可以进一步包括碱性金属涂层如Au来允许与e-NiB层重叠(overplating))。因此，其它的实施方式在以下的权利要求范围内。

Claims (22)

1、用于涂层的方法，包括：
采用非电镀将Ni基的第一材料施涂到基质上；
将Zn基的第二材料施涂到第一材料上；和
将第一和第二材料中的至少一种材料的一种或多种成分扩散到其它当中。
2、权利要求1所述的方法，其中：
将第一材料直接施涂到基质上；和
将第二材料直接施涂到第一材料上。
3、权利要求1所述的方法，其中：
基本上没有另外的材料被施涂。
4、权利要求1所述的方法，进一步包括：
在扩散的至少主要部分之后，施涂Cr基的第三材料。
5、权利要求1所述的方法，进一步包括：
在扩散的至少主要部分之前，施涂Cr基的第三材料。
6、权利要求1所述的方法，其中：
所述扩散包括加热到至少300℃持续至少半小时。
7、权利要求1所述的方法，其中：
所述扩散包括加热到300-500℃持续0.5-3小时
8、权利要求1所述的方法，其中：
所述扩散有效的提供了至少与通过加热到450℃持续1.5小时所得到的高扩散程度同样高的扩散程度。
9、权利要求1所述的方法，其中：
所述扩散有效的提供了至少与通过加热到300℃持续2.0小时所得到的扩散程度同样高的扩散程度。
10、权利要求1所述的方法，其中：
所述基质是Ti基的。
11、权利要求1所述的方法，其中：
第一材料的施涂包括非电NiB镀覆。
12、权利要求1所述的方法，其中：
第一材料的施涂包括在第一位置施涂50-500μm的第一厚度；
第二材料的施涂包括在所述第一位置施涂5-20μm的第二厚度。
13、权利要求1所述的方法，其中：
第一材料的施涂包括施涂基本均匀的第一厚度；和
第二材料的施涂包括施涂基本均匀的小于第一厚度的第二厚度。
14、权利要求1所述的方法，其中：
第一材料，被施涂时，包括1-10％B。
15、权利要求1所述的方法，其中：
第一材料，被施涂时，包括2-6％B。
16、权利要求1所述的方法，其中：
所述扩散形成在所述第二厚度的至少50％的深度中基本上10-25％Ni的区域。
17、由权利要求1的方法形成的被涂覆的基质。
18、用于涂覆的方法，包括：
采用非电镀覆在基质上施涂Ni基的第一材料；
将Zn基的第二材料施涂到第一材料上；
从第一和第二材料形成NiZn合金的步骤。
19、权利要求18所述的方法，其中：
第一材料的的施涂基本上由所述的非电镀覆组成；和
所述形成步骤包括加热到至少400℃的温度持续至少1小时。
20、涂覆的物品，包括：
基质；和
涂覆系统，具有组分梯度，具有：
第一区域，具有：
至少50％的Ni含量；
至少1％的B含量；和
至少10μm的厚度；和
第一区域外的第二区域，具有：
至少50％的Zn含量；
至少10％的Ni含量；和
至少4μm的厚度。
21、权利要求20所述的物品，其中：
所述基质为Ti基的。
22、权利要求20所述的物品，其中：
第一区域Ni含量至少为80％；
第一区域B含量至少为5％；
第二区域Zn含量至少为70％；
第二区域B含量小于第一区域B含量的五分之一；和
所述涂覆系统在第一和第二区域具有过渡区域，厚度不大于10μm。
CNA2006100740849A 2005-04-04 2006-04-04 镍涂覆 Pending CN1847452A (zh)

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