GB2196023A - Low temperature method for applying corrosion resistant alloys to metal articles - Google Patents
Low temperature method for applying corrosion resistant alloys to metal articles Download PDFInfo
- Publication number
- GB2196023A GB2196023A GB08722255A GB8722255A GB2196023A GB 2196023 A GB2196023 A GB 2196023A GB 08722255 A GB08722255 A GB 08722255A GB 8722255 A GB8722255 A GB 8722255A GB 2196023 A GB2196023 A GB 2196023A
- Authority
- GB
- United Kingdom
- Prior art keywords
- corrosion
- resistant
- alloy
- metal
- wetting
- 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- Withdrawn
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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
- 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
- C23C26/00—Coating not provided for in groups C23C2/00 - C23C24/00
- C23C26/02—Coating not provided for in groups C23C2/00 - C23C24/00 applying molten material to the substrate
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Coating By Spraying Or Casting (AREA)
- Other Surface Treatments For Metallic Materials (AREA)
- Organic Low-Molecular-Weight Compounds And Preparation Thereof (AREA)
Abstract
A layer of a wetting metal characterised by having a softening point lower than the temperature at which scaling of the base metal begins is applied preferably by brazing to the base metal of the article and softened by heating to a temperature in a range between the softening point and the melting point of the wetting metal but below the temperature at which scaling of the base metal begins, and a corrosion- resistant alloy is then bonded at a temperature in this temperature range to the softened wetting metal, preferably by arc spraying. Finally, a layer of hard chromium is optionally electrolytically deposited on the surface of the corrosion-resistant alloy. The corrosion resistance of the article is thereby improved.
Description
SPECIFICATION
Low temperature method for applying corrosion resistant alloys
The present invention generally relates to an article of manufacture comprising a metallic member plated with a thin layer of a corrosion-resistant alloy and a method for manufacturing the same.
More particularly, the present invention is directed to a method for applying the corrosionresistant alloy at a low temperature by arc spraying the alloy onto a "wetted" base metal surface at a temperature below the temperature at which the base metal begins to scale.
It is a well known fact that carbon steel tools and parts used in and around water, and particularly salt water, quickly corrode. This corrosion is a leading cause of failure of these items. Corrosion failure is a constant problem which faces the oil and gas industry where drilling operations often employ water-based drilling muds, where the borehole often passes through formations permeated with salt water and particularly in offshore drilling operations where salt spray from the ocean is a constant factor.
In an effort to inhibit this corrosion, steel articles have been plated with corrosion-resistant materials, e.g. stainless steel, chromium and the like. In fact, hard chromed platings have been applied over stainless steel, monel and other corrosion-resistant intermediates to provide improved protection. Although these double coatings do improve the corrosion resistance of the plated articles, failures still occur. Corrosion and failure of these double coated articles often results from problems caused by the high temperature deposition techniques used to apply the intermediate layer. The intermediate layer is often not homogeneous and may include microscopic bubbles, cracks and the like which, although visible only under high magnification, permit moisture to reach the underlying base metal.Such moisture causes initiation of corrosion, and once commenced the corrosion will grow and spread, eventually causing major corrosion problems, including failure and flaking off of the plating layers.
Others have attempted to solve this problem by simply applying the corrosion-resistant alloys to the base metal by conventional spray flame techniques. Articles plated in this manner exhibit poor bonding, also resulting in flaking of the platings. Still others have attempted to apply corrosion-resistant alloys by welding. However, welding techniques may cause distortion of the plated parts. Others have applied the corrosion-resistant alloys using high temperature spray techniques at temperatures as high as 1093 C (2000"F). Although producing plating which exhibits good bonding characteristics, these high temperatures often cause scaling of the underlying base metal resulting in failure. Finally, others have merely used conventional electrolytic or chemical methods for plating nickel or chromium onto the base metal.However, these methods leave many microscopic cracks, permitting eventual corrosion and failure.
Each of the prior methods discussed above suffers from one or more significant problems.
Although each method applies a coating which inhibits corrosion and improves the expected life of the plated articles, all of the prior methods suffer from problems which permit corrosion, flaking or scaling to begin and which eventually lead to a need to replace the article to avoid failure.
Accordingly, there has been a long felt but unfulfilled need for better plating methods and plated articles showing improved resistance to corrosion, and to flaking or scaling of the plating layer.
According to a first aspect of the present invention there is provided a method for applying a corrosion-resistant plating to an exposed surface of a base metal object, characterised by the steps of:
bonding to said exposed surface of said base metal object a layer of a wetting metal having a softening point lower than the temperature at which scaling of said base metal begins;
softening said layer of said wetting metal by heating in a temperature range sufficient to soften said wetting metal but insufficient to produce scaling of said base metal; and
bonding within said temperature range to said softened wetting metal a layer of a corrosionresistant alloy.
According to a second aspect of the present invention there is provided a corrosion-resistant, metallic article, comprising:
a body portion formed of a base metal and having an exposed surface;
a wetting metal bonded to said surface, said wetting metal characterised by having a softening point lower than the temperature at which scaling of said base metal begins; and
a corrosion-resistant alloy bonded to said wetting metal.
The present invention aims to provide an article of manufacture exhibiting improved corrosion resistance, and a method for manufacturing the same. The article comprises a body portion formed of a base metal, often carbon steel, and having an exposed surface. Bonded to the exposed surface is a thin coating of a wetting underlayer characterised by having a softening point lower than the temperature at which scaling of the base metal begins. Preferred underlayer metals include lead, zinc and antimony, alloys of lead and tin and alloys of tin, antimony and copper.Bonded to the wetting underlayer at a temperature between the softening point and the melting point of the wetting underlayer and below the temperature at which scaling of the base metal begins is a layer of a corrosion-resistant alloy selected from the conventional corrosionresistant alloys having iron, chromium, nickel, cobalt or nickel/copper bases. The barrier formed by the combined underlayer and corrosion-resistant alloy exhibits improved homogeneity and imperviousness to water. Optionally, a surface layer of hard chromium may be added to further improve the corrosion and wear resistance of the article.
The method of the present invention provides for heating of the underlayer coated base portion to a temperature between the softening point and the melting point of the underlayer, but below the temperature at which the base metal begins to scale, to "wet" the surface for bonding of the corrosion-resistant alloy. The softened underlayer provides improved "wetting" of the surface of the base metal for application of a thin layer of corrosion-resistant alloy by conventional thermal spray techniques, particularly conventional arc spray methods, in the temperature range stated in the last sentence.
The low temperature application method of the present invention produces a strong, metallurgically bounded, impervious plating barrier of the wetting underlayer metal and corrosionresistant alloy to which a further hard chromium surface may be added to produce articles exhibiting superior corrosion resistance. These and other meritorious features and advantages of the present invention will be more fully appreciated from the following detailed description.
The present invention provides articles of manufacture exhibiting improved corrosion resistance and to methods for manufacturing the same. The basic method comprises producing an impervious barrier on the surface of a base metal article by bonding at low temperatures a corrosionresistant alloy to a softened, wetting underlayer bonded to the base metal. The softened underlayer provides better "wetting" of the surface of the base metal to improve the bond strength, homogeneity and quality. The method of the present invention produces a superior, impervious barrier, essentially free of microscopic bubbles, cracks and the like. This underlayer is bonded- by a strong, metallurgical bond to the base metal. Such a surface eliminates or minimizes many of the corrosion, flaking and scaling problems associated with prior plating methods.
The method of the present invention comprises the initial bonding to a base metal article of a thin, underlayer of a "wetting" metal characterised by having a softening point lower than the temperature at which scaling of the base metal begins. In most applications, the base metal is simply carbon steel. In these cases, exemplary wetting metals include lead, zinc, antimony, the soft solder alloys of lead and babbit alloy. The soft solder alloys of lead often comprise from about 30% to about 95% lead and from about 70% to about 5% tin. Babbit alloy comprises about 91% tin, about 4.5% antimony and about 4.5% copper. The wetting, underlayer metal is bonded to the base metal of the article by brazing or other conventional techniques well known to those skilled in the art.The wetting, underlayer metal is conveniently applied at a thickness A of from 0.025 to 0.125 mm (from 0.001 to 0.005 inch) and preferably from 0.050 to 0.075 mm (from 0.002 to 0.003 inch) in thickness.
In an alternative method, the surface of the base metal article is roughened by sand blasting or other techniques well known to those skilled in the art. To the roughened surface is bonded by conventional spray techniques a thin layer of Nichrome or equivalent material sprayed to the same thickness A. The solder or other wetting metal is applied to the Nichrome-coated base metal article as described above. Fusing at a temperature near or above the melting point of the wetting metal causes the wetting metal to fill the interstices around the Nichrome particles as the result of capillary action.This embodiment produces a smooth, impervious underlayer exhibiting greater strength as a result of the strong, metallurgical bond between the base metal and the
Nichrome layer.
The method further comprises heating the wetting metal, previously bonded to the base metal article by either method described above,. to a temperature above its softening point and preferably below its melting point, but below the temperature at which scaling of the base metal begins. Heating to a temperature within this range softens the wetting metal while not causing the base metal to scale. For example, alloys comprising about 70% tin and 30% lead may be heated to about 204"C (400 F). As the percentage of tin decreases, the preferred temperature increases to about 316"C (600"F) for an alloy comprising about 5% tin and about 95% lead.
When pure lead is used as the wetting, underlayer metal, softening temperatures of about 343"C (650"F) are preferred. Temperatures of about 371"C (700"F) are preferred with babbit alloy.
Finally, temperatures of about 427"C (800"F) and 593"C (1100 F) are preferred when zinc and antimony, respectively, have been used as the wetting, underlayer metal.
To the softened, wetting, underlayer metal is bonded a layer of a corrosion-resistant alloy.
This alloy is applied by conventional thermal spray techniques well known to those skilled in the art, preferably arc spraying, at a temperature above the softening point and below the melting point of the wetting, underlayer metal and below the temperature at which the base metal begins to scale. Conventional corrosion-resistant alloys applicable within the stated temperature range may be employed. The following are exemplary corrosion-resistant alloys which may be used with a carbon steel base and the wetting metals listed above. Exemplary iron-based alloys include 304 stainless steel, 316 stainless steel and A-286. An exemplary chromium-based alloy is 80 chromium/20 nickel. Exemplary cobalt-based alloys include Haynes Alloy 25, Multimet
Alloy and MP-35N. Exemplary nickel-based alloys include Inco 718, Inco 625, Inco 925, Inco
X750, Hasteloy G and Hasteloy C-276.Finally, exemplary nickel-copper-based alloys include
Monel 400 and Cupro Nickel. The corrosion-resistant alloy layer is conveniently applied in a thickness of from about 0.25 to 1.25 mm (0.010 to 0.050 inch) and preferably from 0.625 to 0.889 mm (0.025 to 0.035 inch).
The chemical compositions of the above alloys and their equivalents are well known to those skilled in the art and, in fact, have been compiled and published in tables by the American
Society of Mechanical Engineers. Further, these and other alloys of defined compositions have been assigned identification numbers for easy reference in the ASME/ANSI Unified Metal Numbering System.
TABLE I
Common Alloy Tradename ASME/ANSI Unified Number
Type 304 S30400
Type 316 S31600
A-286 S66286 Monel 400 N04400
CuproNickel C71500 INCO 718 N07718 INCO 625 N06625 INCO 925 N06695
Hasteloy G N06007
Hasteloy C-276 N10276 INCO X750 N07750
Haynes Alloy 25 N08325
MP-35N R30035
The method of the present invention produces an article of manufacture having a superior, corrosion-resistant plating applied thereto comprising a nearly impervious barrier of the wetting, underlayer metal combined with the corrision-resistant alloy. This barrier is metallurgically bonded to the base metal. Because this plating is metallurgically bonded to the base metal, this plating resists flaking.Because the plating exhibits improved homogeneity and freedom from microscopic bubbles and cracks, it offers superior resistance to corrosion.
The corrosion and wear resistance of the article may be further improved by hard chroming over the corrosion resistant alloy using conventional electrolytic hard chroming methods well known to those skilled in the art.
EXAMPLE 1
A layer about 0.050 mm (0.002 inch) thick of lead alloy solder (70% tin/30% lead) was brazed on the surface of a clean, tubular carbon steel test piece. The test piece, including the solder brazed on the surface thereof, was heated to about 232"C (450"F) to soften the solder.
A layer of Monel 400 about 0.75 mm (0.030 inch) thick was arc sprayed on the softened solder at this temperature. After grinding the composite barrier of solder and Monel 400 to a thickness of about 0.381 mm (0.015 inch), the test piece was electrolytically plated with a hard chromium layer about 0.125 mm (0.005 inch) in thickness.
EXAMPLE 2
A second test piece was produced in accord with the method set forth in Example 1 with the exception that the thickness of the wetting solder was about 0.075 mm (0.003 inch) and the thickness of the corrosion-resistant alloy was about 1.14 mm (0.045 inch). This composite barrier was ground to a thickness of about 0.75 mm (0.030 inch) and electrolytically hard chromed with a layer about 0.125 mm (0.005 inch) in thickness.
The test piece of Example 2 was similarly subjected to a continuous salt spray fog in accord with the procedure set forth in ASTM B-117-73. This test piece was examined after 1,000 hours and no corrosion was evident.
Claims (17)
1. A method for applying a corrosion-resistant plating to an exposed surface of a base metal object, characterised by the steps of:
bonding to said exposed surface of said base metal object a layer of a wetting metal having a softening point lower than the temperature at which scaling of said base metal begins;
softening said layer of said wetting metal by heating in a temperature range sufficient to soften said wetting metal but insufficient to produce scaling of said base metal; and
bonding within said temperature range to said softened wetting metal a layer of a corrosionresistant alloy.
2. A method according to claim 1 wherein said softening step further comprises heating said wetting metal to a temperature sufficient to melt said wetting metal.
3. A method according to claim 1 or 2 wherein said bonding step comprises:
bonding to said exposed surface a layer of a 77Ni:20Cr nichrome alloy;
bonding to said exposed surface and to said nichrome alloy a layer of said wetting metal; and
fusing said wetting metal and said nichrome alloy to said exposed surface.
4. A method according to any one of the preceding claims wherein said corrosion-resistant alloy is arc sprayed onto said softened wetting metal at a temperature within said temperature range.
5. A method according to any one of the preceding claims, comprising the further step of bonding a layer of hard chromium to said corrosion-resistant alloy.
6. A method according to claim 5 wherein said chromium is bonded electrocally to said corrosion-resistant alloy.
7. A corrosion-resistant, metallic article, comprising:
a body portion formed of a base metal and having an exposed surface;
a wetting metal bonded to said surface, said wetting metal characterised by having a softening point lower than the temperature at which scaling of said base metal begins; and
a corrosion-resistant alloy bonded to said wetting metal.
8. A corrosion-resistant, metallic article as claimed in claim 7 wherein said base metal is a carbon steel.
9. A corrosion-resistant, metallic article as claimed in claim 7 or 8 wherein said wetting metal is selected from lead, zinc, antimony, alloys of lead and tin and alloys of tin, antimony and copper.
10. A corrosion-resistant, metallic article as claimed in claim 9 wherein said wetting metal is an alloy of lead and tin.
11. A corrosion-resistant, metallic article as claimed in claim 10 wherein said alloy comprises from 30 to 95% lead and from 70 to 5% tin.
12. A corrosion-resistant, metallic article as claimed in claim 9 wherein said wetting metal is an alloy comprising 91% tin, 4.5% antimony and 4.5% copper.
13. A corrosion-resistant, metallic article as claimed in any one of claims 7 to 12 further comprising a layer of 77Ni:20Cr nichrome alloy bonded to said surface and wherein said wetting metal is fused to said surface and said nichrome alloy.
14. A corrosion-resistant, metallic article as claimed in any one of claims 7 to 13 wherein said corrosion resistant alloy is selected from stainless steels, chromium based alloys. cobalt based alloys, nickel based alloys and nickel/copper based alloys.
15. A corrosion-resistant, metallic article as claimed in any one of claims 7 to 14 further comprising a layer of hard chromium electrolytically bonded to said corrosion-resistant alloy.
16. A method of plating a surface with a corrosion-resistant alloy, substantially as described in any of the foregoing Examples.
17. A metalic article having a surface which is plated with a corrosion-resistant alloy. substantially as described in any of the foregoing Examples.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US91883786A | 1986-10-14 | 1986-10-14 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| GB8722255D0 GB8722255D0 (en) | 1987-10-28 |
| GB2196023A true GB2196023A (en) | 1988-04-20 |
Family
ID=25441041
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB08722255A Withdrawn GB2196023A (en) | 1986-10-14 | 1987-09-22 | Low temperature method for applying corrosion resistant alloys to metal articles |
Country Status (4)
| Country | Link |
|---|---|
| FI (1) | FI874213A (en) |
| GB (1) | GB2196023A (en) |
| NO (1) | NO872722L (en) |
| SE (1) | SE8703978L (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2386944A (en) * | 2002-03-26 | 2003-10-01 | Ken Ford | A ventilation system for an agricultural building |
| EP1752560A1 (en) * | 2005-08-10 | 2007-02-14 | Wärtsilä Schweiz AG | Article protected against high temperature corrosion and reciprocating piston internal combustion engine or turbine or combustion unit containing the article. |
| EP2039412A2 (en) | 2007-09-21 | 2009-03-25 | Wärtsilä Schweiz AG | Exhaust gas particle filter and method for manufacturing an exhaust gas particle filter |
Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB362608A (en) * | 1929-11-27 | 1931-12-10 | Wmf Wuerttemberg Metallwaren | Method of electroplating metal alloys containing chromium |
| GB796128A (en) * | 1956-12-13 | 1958-06-04 | Husqvarna Vapenfabriks Ab | Sintered metal objects and the manufacture thereof |
| GB808380A (en) * | 1956-02-10 | 1959-02-04 | Lucas Industries Ltd | Silver deposition on metal parts |
| GB812378A (en) * | 1955-01-20 | 1959-04-22 | Giuseppe Zappa | A method of applying to a metal object, by means of a spraygun, a thickness or layer of bronze |
| GB822366A (en) * | 1956-09-10 | 1959-10-21 | Coal Industry Patents Ltd | Improvements in and relating to the protective coating of articles of aluminium or alloys of aluminium |
| GB826057A (en) * | 1957-03-15 | 1959-12-23 | Glacier Co Ltd | Bearings |
| US4296181A (en) * | 1980-01-16 | 1981-10-20 | Nehra Samuel A | Plating method and structure |
-
1987
- 1987-06-29 NO NO872722A patent/NO872722L/en unknown
- 1987-09-22 GB GB08722255A patent/GB2196023A/en not_active Withdrawn
- 1987-09-25 FI FI874213A patent/FI874213A/en not_active Application Discontinuation
- 1987-10-13 SE SE8703978A patent/SE8703978L/en not_active Application Discontinuation
Patent Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB362608A (en) * | 1929-11-27 | 1931-12-10 | Wmf Wuerttemberg Metallwaren | Method of electroplating metal alloys containing chromium |
| GB812378A (en) * | 1955-01-20 | 1959-04-22 | Giuseppe Zappa | A method of applying to a metal object, by means of a spraygun, a thickness or layer of bronze |
| GB808380A (en) * | 1956-02-10 | 1959-02-04 | Lucas Industries Ltd | Silver deposition on metal parts |
| GB822366A (en) * | 1956-09-10 | 1959-10-21 | Coal Industry Patents Ltd | Improvements in and relating to the protective coating of articles of aluminium or alloys of aluminium |
| GB796128A (en) * | 1956-12-13 | 1958-06-04 | Husqvarna Vapenfabriks Ab | Sintered metal objects and the manufacture thereof |
| GB826057A (en) * | 1957-03-15 | 1959-12-23 | Glacier Co Ltd | Bearings |
| US4296181A (en) * | 1980-01-16 | 1981-10-20 | Nehra Samuel A | Plating method and structure |
Non-Patent Citations (1)
| Title |
|---|
| WO 83/02087 * |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2386944A (en) * | 2002-03-26 | 2003-10-01 | Ken Ford | A ventilation system for an agricultural building |
| GB2386944B (en) * | 2002-03-26 | 2004-10-06 | Ken Ford | Agricultural buildings |
| EP1752560A1 (en) * | 2005-08-10 | 2007-02-14 | Wärtsilä Schweiz AG | Article protected against high temperature corrosion and reciprocating piston internal combustion engine or turbine or combustion unit containing the article. |
| EP2039412A2 (en) | 2007-09-21 | 2009-03-25 | Wärtsilä Schweiz AG | Exhaust gas particle filter and method for manufacturing an exhaust gas particle filter |
Also Published As
| Publication number | Publication date |
|---|---|
| SE8703978L (en) | 1988-04-15 |
| FI874213A0 (en) | 1987-09-25 |
| NO872722L (en) | 1988-04-15 |
| GB8722255D0 (en) | 1987-10-28 |
| SE8703978D0 (en) | 1987-10-13 |
| NO872722D0 (en) | 1987-06-29 |
| FI874213A (en) | 1988-04-15 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| WAP | Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1) |