EP1042078A1 - Procede d'obturation de revetements - Google Patents

Procede d'obturation de revetements

Info

Publication number
EP1042078A1
EP1042078A1 EP98964057A EP98964057A EP1042078A1 EP 1042078 A1 EP1042078 A1 EP 1042078A1 EP 98964057 A EP98964057 A EP 98964057A EP 98964057 A EP98964057 A EP 98964057A EP 1042078 A1 EP1042078 A1 EP 1042078A1
Authority
EP
European Patent Office
Prior art keywords
coating
substrate
fluoropolymer
recited
porous
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Withdrawn
Application number
EP98964057A
Other languages
German (de)
English (en)
Inventor
Andrew Kelsey Birchenall
Paul Douglas Brothers
Jeffrey A. Hrivnak
Richard James Merigold
Richard Alan Morgan
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
EIDP Inc
Original Assignee
EI Du Pont de Nemours and Co
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by EI Du Pont de Nemours and Co filed Critical EI Du Pont de Nemours and Co
Publication of EP1042078A1 publication Critical patent/EP1042078A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
    • B05D5/08—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain an anti-friction or anti-adhesive surface
    • B05D5/083—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain an anti-friction or anti-adhesive surface involving the use of fluoropolymers
    • B05D5/086—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain an anti-friction or anti-adhesive surface involving the use of fluoropolymers having an anchoring layer

Definitions

  • the present invention relates to a process and material for sealing the pores of a coating, which material may be applied by spraying, dipping or brushing.
  • the material can also be used to coat the first coating, as well as provide for attachment of a fluoropolymer coating.
  • One material useful in the process is .an amorphous fluoropolymer solution.
  • Thermal spray deposition of one material on the surface of another is well- known to those skilled in the .art.
  • One common technique, for example, is known as the high velocity oxy-fuel (HVOF) technique. See generally R. Irving, et al., Welding Journal 72(7), 1993, pp. 25-30.
  • HVOF high velocity oxy-fuel
  • Such thermal spray techniques can be used to deposit corrosion-resistant materials on corrosion-susceptible substrates in a low-cost approach to corrosion control.
  • HVOF guns consist essentially of an internal combustion chamber into which a gaseous or liquid fuel •and oxygen .are injected at high pressures (0.5-3.5 Mpa, 80-500 lb/in 2 ) and high flow rates, up to 0.016 m 3 /s ( ⁇ 2000 surface ft 3 /h). These products .are then ignited and continuously combusted, the resulting fl.ame being allowed to expand supersonically and exit to atmosphere through a long nozzle simile to that of a rocket motor, as indicated by the presence of characteristic "shock diamonds" in the flame. Powder is injected into, or downstre.am of, the combustion chamber and particles are heated and accelerated by the flame.
  • sprayed layer has inherent porosity, with interconnected pathways along the boundaries of the sprayed material deposited as semi-molten "splats" which impinge first the substrate and then on previous layers of “splats".
  • a “splat” is herein defined as a metal droplet which spreads upon impact with the substrate.
  • Reactive or corrosive liquids or vapors such as would be encountered in chemical processing vessels, valves and the like, can penetrate through these connected pores and reach the substrate/coating interface, causing corrosion of the substrate, blistering at the substrate/coating interface, and spalling of the thermally sprayed layer. A better way to enhance the corrosion resistance of such structures is needed.
  • Copolymers of tetrafluoroethylene and perfluoro(ethyl vinyl ether) disclosed heretofore have been crystalline copolymers. See, for example, U.S. Pat. Nos. 3,635,926 .and 5,461,129. Amorphous copolymers of tetrafluoroethylene and perfluoro(ethyl vinyl ether) .are disclosed in U.S. Pat. Nos. 5,478,905, 5,637,663 and 5,663,255, and in commonly owned, co-pending application Serial No. 08/929,213, which are incorporated herein by reference. It is known in the .art to coat porous metal coatings with fluoropolymer dispersions. See, for example, U.S.
  • German Patent Application DE 19530194 A 1 also discloses the use of fluoropolymer dispersions to coat kitchen appliances.
  • Spanish Patent Application ES 8605591 A similarly discloses the use of fluoropolymer dispersions.
  • U.S. Pat. No. 4,684,677 discloses the use of a thermosetting solvent solution primer comprising, in part, a fluorocarbon polymer, to coat a substrate, but there is no mention of its use to seal pores.
  • U.S. Pat. No. 5,178,916 discloses the use of a low molecular weight fluorocarbon solution to seal the porosity in a gold plated article, but this plating layer is not applied by thermal spray. Additionally, the molecular weight of the fluoropolymer used in the solution of the present invention is in the range of 200,000 to 400,000, much higher than disclosed in the '916 patent.
  • U.S. Pat. No. 5,238,471 discloses the use of a spray-applied fluoropolymer film onto a porous membrane, but no solid substrate or thermal-spray coating is disclosed.
  • U.S. Pat. No. 5,660,934 discloses a high temperature thermal sprayable material which adheres to the surface of a thermal sprayable plastic particle to form a cladding layer thereon.
  • the plastic particle may be comprised of a fluoropolymer.
  • JP H9-300361 A discloses, in relation to golf ball production technology, the coating of a substrate with a first metal coated by electroplating and than joining a second, non-metal coating, to that first coating. It is not clear from this publication whether there is any porosity in the first coating.
  • the present invention concerns a process for coating a substrate comprising the following steps: a) applying to said substrate a coating that contains pores; and b) applying a fluoropolymer solution to said coating to seal said pores.
  • the invention further concerns .an improvement in a process for the coating of a substrate, wherein a first coating having porous regions has been applied to the substrate to form a first coated substrate, the improvement comprising applying to said first coated substrate a second coating comprising a fluoropolymer solution, such that the second coating seals up porosity of the first coating, resulting in a substantially non-porous second coated substrate.
  • a fluoropolymer coating solution is applied to a metal coating, for example, the porosity is decreased from about 0.25% to less than about 0.03%, in the areas penetrated by the solution.
  • the invention also concerns coated articles, comprising substrates coated with the sealed, non-porous coatings made as described above with materials as described below.
  • the coatings described herein are useful for coating process vessels and electronic parts, where non-porous surfaces are desirable.
  • the invention further comprises a process of coating a substrate comprising the steps of: a) applying to said substrate a coating that may contain pores, said coating comprising a polymeric material in a range of about 5 weight % to about 30 weight %; and b) effecting removal of said polymeric material, thereby forming voids in said coating.
  • said polymeric material is a fluoropolymer.
  • the fluoropolymer may be dissolved in a solvent which flows through the coating to fill voids at the coating-substrate interface.
  • the porous coating may additionally be comprised of a second coating of fluoropolymer solution which is in contact with said fluoropolymer in said porous coating.
  • the process above may be further comprised of the steps of coating said porous coating with a fluoropolymer dispersion, and sintering said fluoropolymer to effect joining of the resulting fluoropolymer layer to said fluoropolymer in said porous coating.
  • Various materials may be used as coating herein and are described below.
  • One sort of material usable as a preferred coating in the present invention is an amorphous fluoropolymer, comprising copolymerized units of tetrafluoroethylene (TFE) and perfluoro(ethyl vinyl ether) (PEVE).
  • TFE tetrafluoroethylene
  • PEVE perfluoro(ethyl vinyl ether)
  • One embodiment of this amorphous fluoropolymer includes units of one or more additional fluorinated monomers.
  • Preferred additional monomers include perfluoro(methyl vinyl ether) (PMVE). When perfluoro(methyl vinyl ether) is present in the fluoropolymer, perfluoro(ethyl vinyl ether) is at least 15% of the combined weight of the combined perfluoro(ethyl vinyl ether) and perfluoro(methyl vinyl ether).
  • Further coatings suitable for use in the present process include amorphous fluoropolymers containing units of functional fluorinated comonomers or nonfunctional comonomers.
  • Figure 1 shows a substrate coated with a thermal sprayed inner coating having pores and adhered to a fluoropolymer solution sealant.
  • Figure 2 shows a substrate coated with an adherent, sintered fluorochemical coating on a thermal spray composite containing a fluorochemical.
  • Figure 3 shows a substrate coated with an adherent solution-deposited soluble fluorochemical coating on a thermal spray composite containing soluble fluorochemical.
  • Figure 4(a) shows a substrate coated with a void-filled coating made by heating thermally sprayed polymer containing a composite.
  • Figure 4(b) shows the s-ame material after heating to 500°C.
  • Figure 5(a) shows a substrate coated with a void-filled coating.
  • Figure 5(b) shows the same material after exposure to a solvent.
  • Figure 6(a) shows an electron micrograph of a cross-section of a thermal spray coating (Inconel®) having a pore, which has a soluble fluoropolymer coating applied.
  • Figure 6(b) shows an x-ray image of the same cross-section, identifying the nickel in the Inconel®.
  • Figure 6(c) shows the same cross-section, but identifies the fluoropolymer on the surface and in the pore.
  • thermal spray technology is used throughout the industry to apply protective coatings, e.g., relatively low temperature aqueous corrosion protection of corrosion susceptible substrates.
  • the technology is particularly attractive because it can be used to rework existing equipment that may experience corrosion and/or wear problems.
  • the results have often been less than optimum, because corrosion still takes place and the thermal spray coatings tend to blister.
  • Sealing the inherent porosity of a thermal spray coating is an important step in the production of a composite coating.
  • composite coating herein is meant a coating comprising more than one layer or more th.an one material.
  • One method of sealing the pores is to use an organic fluid which flows into the pores.
  • epoxies and furan have been used for this purpose, as well as poly (tetrafluoroethylene) (PTFE) and related fluoropolymer dispersions.
  • Dispersions of these fluoropolymers which are comprised of fine particles, are generally very useful at operating conditions which allow the particles to sinter or after a particle sintering heat treatment.
  • the use of solutions of fluoropolymers with molecular weights in the range of 200,000 to 400,000 are an improvement in that the heat treatment requirement is avoided .
  • These fluoropolymers are known to have excellent chemical resistance.
  • a perfluorinated one such as perfluorooctane (3M, Minneapolis, MN).
  • An amorphous polymer is one which does not contain crystallinity when me-asured by DSC, or whose heat of melting is less than 2 J/g.
  • the fluoropolymers include but are not limited to copolymers of TFE with functional or non-functional monomers such as fluoroolefins having 2-8 carbon atoms and fluorinated alkyl vinyl ether in which the alkyl group contains 1 or 3 to 5 carbon atoms.
  • functional or non-functional monomers such as fluoroolefins having 2-8 carbon atoms and fluorinated alkyl vinyl ether in which the alkyl group contains 1 or 3 to 5 carbon atoms.
  • non-functional monomers include hexafluoro- propylene (HFP), chlorotrifluoro ethylene (CTFE), PEVE, PMVE .and perfluoro- (propylene vinyl ether) (PPVE).
  • Functional monomers include perfluoroethyl vinyl ether (EVE), CF 2 CFOCF2CFCF3OCF 2 CF 2 COOCH3 (EVE-carbamate), CF 2 CFOCF 2 CFCF3 ⁇ CF 2 CF 2 S ⁇ 2F (PSEPVE), CF 2 CFOCF 2 CFCF 3 OCF 2 CF 2 CN (8CNVE), N 3 (CF 2 CFOCF 2 CFCF 3 OCF 2 CF 2 )3 (EVE-triazine), CF 2 CFOCF 2 CFCF 3 OCF 2 CF 2 CN (EVE-CN), CF 2 CFOCF 2 CFCF 3 OCF 2 CF 2 CH 2 OH (EVE-OH), CF 2 CFOCF 2 CFCF 3 OCF 2 CF 2 CH 2 PO 2 (OH) 2 (EVE-P) and CF 2 CFOCF 2 CFCF 3 OCF 2 CF 2 CH 2 COOH (EVE-COOH).
  • EVE perfluoroethyl vinyl ether
  • Teflon® SF60 Teflon® SF60 (TFE/PMVE/PEVE, DuPont, Wilmington DE), Teflon® SF61 (TFE/PMVE/PEVE/EVE-P), Teflon® SF50 (TFE/HFP), Teflon® AF 1600
  • the fluoropolymer solutions may be applied to the porous coating and articles comprising these coatings by common coating methods, including but not limited to spray application, dipping and brushing.
  • Any structural material can be used as a substrate in this invention, such as metals, ceramics and composites
  • metals include carbon steel, stainless steel, aluminum, copper .and the like and ceramics include alumina and silica.
  • Preferred substrates include carbon steel, aluminum and copper, as these metals generally are the least expensive. However, most of these are corrosion-prone.
  • a variety of materials can be applied to substrates via thermal spray deposition to form a porous coating. These materials include metals such as Alloy 625 (Inconel® 625, Inco, Inc. Huntingdon, WV), Alloy C (Hastelloy® C, Haynes, Inc., Kokomo, IN), .and type 316 stainless steel; ceramics such as tungsten carbide .and chrome oxide; polymers such as Teflon® and Tefzel ® (both from DuPont Co., Wilmington, DE); and composites such as tungsten carbide in a cobalt matrix.
  • Alloy 625 Inconel® 625, Inco, Inc. Huntingdon, WV
  • Alloy C Hastelloy® C, Haynes, Inc., Kokomo, IN
  • .and type 316 stainless steel ceramics such as tungsten carbide .and chrome oxide
  • polymers such as Teflon® and Tefzel ® (both from DuPont Co., Wilmington
  • various metals may be coated onto a substrate via electroplating.
  • One of these metals is gold, which is often used for electronic components.
  • Pore distributions are generally a function of the thermal spray material and thermal spray process parameters.
  • One method of measuring the pore distribution is to use mercury porosimetry. This technique measures pore distribution as the pressure is increased on a reservoir of mercury. At higher and higher pressure, the mercury is forced into smaller and smaller pores, indicating the pore distribution. Once the initial porosity is measured, the fluoropolymer solution is applied, and the porosity remeasured, which indicates how well the pores have been sealed by the coating.
  • Another important consideration in selecting the method of sealant application is to determine the penetration depth of the sealant into the pores below the surface. This is important because the surface film itself may be subject to corrosion or wear and the sealing action provided by the film on the surface may not prove to be durable in some applications.
  • One way to measure the penetration depth is to use x-ray fluorescense .analysis (this is done with a scanning electron microscope (SEM) with a microprobe on metallographic cross sections). This is shown in Figure 6, that is further described below.
  • Penetration depth is dependent on parameters such as pore distribution, sealant application technique and fluoropolymer molecular weight and solution concentration. It is generally preferred that the porosity of the porous metal coating be decreased to less than about 0.025% of the original amount after coating with the fluoropolymer solution.
  • One benefit of this invention is the relative increase in corrosion resistance seen in sealed articles as compared to those articles which are not sealed.
  • the increase in corrosion-resistant lifetime is at least by a factor of 8. This becomes significant when the .articles treated by the process are process vessels, pipes, valves and the like, as are often found in chemical industry plants. When these process .articles corrode, they usually must be replaced, involving plant downtime and thus lost revenues, as well as causing potential safety considerations.
  • This invention allows already existing plant components to be coated and sealed in situ, thus obviating the problems mentioned above.
  • Substrates which have been prepared by thermally spraying with a composite layer generated by the present invention, in which the final coating is a non-stick polymer resin may be used in bakeware and top of the stove cookware.
  • Other uses of such coated and sealed substrates include saws, hot plates, show molds, snow shovels, plows, ship bottoms, dies and tools.
  • a polymer-filled composite coating is first deposited by thermal spray.
  • the coating is then heated to a relatively high temperature (for example about 500°C) to vaporize the polymer constituent of the composite. This leaves the high melting point constituent on the substrate with voids where the polymer was previously, before vaporization.
  • a polymer soluble in selected solvents e.g., alkanes and perfluoralkanes
  • Figures 1 through 5 show various configurations for the layers of the coating.
  • Figure 1 shows a thermal sprayed inner coating 7 adhered to an outer coating of fluoropolymer solution 8, e.g. Teflon®, E.I. du Pont de Nemours .and Company, Wilmington, Delaware.
  • fluoropolymer solution 8 e.g. Teflon®, E.I. du Pont de Nemours .and Company, Wilmington, Delaware.
  • Figure 2 is a dual layer coating.
  • the inner layer can be produced by electroplating or by thermal spray technology.
  • the outer coating is produced by sintering a dispersion of fluorochemical particles. It is preferred to use thermal spray, rather than electroplating, for producing the inner layer as thermal spray can deliver non-conducting ceramic type materials as a high melting point constituent of the composite, while electroplating can only deliver metals.
  • outer fluorochemical sintered coating 1 is joined to surface particles if thermal spray high melting point material 2 and a thermal spray fluorochemical consituent 3.
  • the substrate can be, for example, carbon steel.
  • thermal spray technology has deposited a soluble inner coating layer 4, e.g. a soluble fluorochemical, along with a high melting point constituent 5.
  • the outer layer 6 is deposited from a solution of soluble polymer. Outer layer 6 joins to surface particles 4 and 5 of the inner layer.
  • Fig. 4(a) shows a substrate coated with a mixture of thermal sprayed fluoropolymer 9 and high melting point constituent 10, which is then heated to 500 degrees C for about 30 minutes. Upon heating voids 11 form. These voids may then serve to hold finish on fiber finish rolls, for example.
  • Figure 5(a) shows a substrate coated with a mixture of thermal sprayed fluoropolymer 12 and high melting point constituent 13. Upon exposure to a solvent voids are created by removal of soluble polymer particles as shown in Figure 5(b).
  • Useful solvents include .any perfluorinated solvent, such as perfluorooctane (PF-5080, 3M Co., Minneapolis, MN). Penetration of the solution is determined by the viscosity of the solution .and the size and shape of pore distribution. The solvent can form a seal deep within the coating. A seal that remains deep within the composite, is protected from erosion or corrosion.
  • Figures 6(a), 6(b) and 6(c) show three images of a large pore at the external surface of an Inconel® 625 thermal spray coating produced by the HVOF technique which was subsequently coated with a soluble fluoropolymer.
  • the images were obtained using an electron microprobe with two types of spectrophotometric detectors, which both discriminate x-ray information, from Cameca Instruments, Inc., Trumbull, CT (model SU30).
  • the instrument operated at 15 KV with a beam current of 4nA.
  • the first detector was a wavelength dispersive spectometer analyzing crystal, PCI, 2d spacing of 61.20 nm, which was peaked on the fluorine Ka.
  • the second detector was an energy dispersive spectrometer window peaked on 7477 eV, the Ka line of nickel.
  • the images and maps were acquired with software from Princeton Gamma-Tech, Princeton, NJ. This was accomplished by selecting a Ni Ka region of interest from the EDS spectra and also an external source referencing the first detector.
  • the software scans the electron beam across the area to be analyzed.
  • the beam dwell time is 0.05 seconds per point at a resolution of 256 points full width. This horizontal scan is repeated with tan appropriate offset to generate an image iwth a vertical resolution of 200 points.
  • the maps pictured in Figures 6(a), 6(b) and 6(c) are 256x200 points.
  • Figure 6(a) shows an image of the surface derived from the energy dispersive scan.
  • Figure 6(b) shows the s.ame surface, showing only the collection of nickel x-rays by the microprobe. Nickel is the major constituent of the alloy, and thus this image shows the location of the metal in the coating.
  • Figure 6(c) shows the same surface, but this time a collection of fluorine x-rays is shown, obtained with the wavelength dispersive spectrometer. A deposit of fluoropolymer of about 7 ⁇ m thick is shown on the top, external surface of the coating, as shown by the lighter areas. Additionally, it can be seen by the lighter areas that the fluoropolymer has penetrated into the large pore to a depth of about 70 ⁇ m below the surface.
  • the agitator was turned on at 100 rpm, the temperature was increased to 90°C, and the pressure was increased to 400 psig (2.86 MPa) by addition of a mixture of 27.2 wt% TFE, 51 wt% perfluoro(methyl vinyl ether) (PMVE), and 21.8 wt% PEVE.
  • the wet resin was rinsed with demineralized water three times with vigorous agitation, and dried at 80°C under vacuum.
  • the TFE/PMVE/PEVE/EVE-P copolymer was prepared as the TFE/PMVE/PEVE copolymer described above, except that 15 mL of EVE-P were ch-arged along with the C-9, the APS initiator solution concentration was 6.0 g/L, and the initiator solution pumping rate after kickoff was 3.25 mL/min. Solids content of the raw dispersion was 24.3 wt%.
  • the product resin contained 54.0 wt% of TFE, 30.4 wt% of PMVE, and 15.6 wt% of PEVE and EVE-P combined, as determined by 19 F NMR.
  • the amount of EVE-P in the copolymer was less than 1 wt%. No crystalline melting point was detected by DSC.
  • the weight average molecular weight was 205,000.
  • the HVOF thermal spray process had the following parameters.
  • the alloy coating was deposited using a Jet Kote® IIA sprayer (Stellite Coatings, Inc.).
  • Powder Carrier Gas Argon CCaarrririeerr GGaass FFllooww 40 cfh (80 psi) Powder Feed Rate 2 rpm Spray Distance 11" Part Speed 17% rpm @ 5% dX/dt, at a radius of 4" Spray Time 46 passes CCoooolliinngg None Substrate 3" x 3" Carbon Steel Substrate Thickness 0.195" Surface Preparation Grit Blast with #12 Al 2 O 3 , Ultrasonic
  • Corrosion Testing were run using a 4-neck cylindrical cell ("atlas cell") generally as described in ASTM C-868 with 3-in (7.6 cm) square test panels, and with the cell half full of 1% sulfuric acid. The test temperature was 60°C.
  • the test panels were coated plates, with Inconel Alloy 625, a corrosion resistant alloy, applied by the HVOF procedure outlined above onto a carbon steel substrate. Panels were tested with the alloy side toward the acid solution. Both unsealed panels and panels sealed with PEVE copolymers were exposed.
  • Amorphous PEVE copolymers used were a TFE/PMVE/PEVE copolymer and a TFE/PMVE/PEVE/EVE-P copolymer, generally prepared by the procedure described in the copending application described above. Coatings were applied from 3 wt % solutions in perfluorooctane (PF-5080, 3M Co., Minneapolis, MN). Panels were cleaned, first with acetone, then with CF-113. The clean panels were dipped twice in the copolymer solutions, drying at 150°C after each dip. The unsealed panels failed by blistering at the liquid/vapor interface after 3 weeks of exposure.
  • PF-5080 perfluorooctane

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Abstract

L'invention concerne un procédé de revêtement d'un substrat, le procédé consistant à: appliquer sur le substrat un revêtement poreux; puis à appliquer une solution de fluoropolymère sélectionnée, afin d'obtenir un substrat durable revêtu non poreux.
EP98964057A 1997-12-22 1998-12-18 Procede d'obturation de revetements Withdrawn EP1042078A1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US6843197P 1997-12-22 1997-12-22
US68431P 1997-12-22
PCT/US1998/026903 WO1999032234A1 (fr) 1997-12-22 1998-12-18 Procede d'obturation de revetements

Publications (1)

Publication Number Publication Date
EP1042078A1 true EP1042078A1 (fr) 2000-10-11

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WO (1) WO1999032234A1 (fr)

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