US20240076794A1 - Metallic component with a ceramic coating - Google Patents
Metallic component with a ceramic coating Download PDFInfo
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- US20240076794A1 US20240076794A1 US17/929,960 US202217929960A US2024076794A1 US 20240076794 A1 US20240076794 A1 US 20240076794A1 US 202217929960 A US202217929960 A US 202217929960A US 2024076794 A1 US2024076794 A1 US 2024076794A1
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- metallic component
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- corrosion
- copper
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- 238000005524 ceramic coating Methods 0.000 title description 16
- 238000000576 coating method Methods 0.000 claims abstract description 34
- 239000011248 coating agent Substances 0.000 claims abstract description 28
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 14
- 229910052802 copper Inorganic materials 0.000 claims abstract description 13
- 239000010949 copper Substances 0.000 claims abstract description 13
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 11
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 9
- 239000010959 steel Substances 0.000 claims abstract description 9
- 238000000034 method Methods 0.000 claims description 25
- 238000007599 discharging Methods 0.000 claims description 9
- 238000000151 deposition Methods 0.000 claims description 4
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 claims description 3
- 239000011244 liquid electrolyte Substances 0.000 claims description 3
- 239000000126 substance Substances 0.000 claims description 3
- 229910021502 aluminium hydroxide Inorganic materials 0.000 claims 2
- 230000001131 transforming effect Effects 0.000 claims 1
- 238000005260 corrosion Methods 0.000 abstract description 19
- 238000009413 insulation Methods 0.000 abstract description 13
- 238000004804 winding Methods 0.000 abstract description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 15
- 239000003792 electrolyte Substances 0.000 description 10
- 230000007797 corrosion Effects 0.000 description 9
- 229910052742 iron Inorganic materials 0.000 description 8
- 238000007745 plasma electrolytic oxidation reaction Methods 0.000 description 8
- 239000000919 ceramic Substances 0.000 description 7
- 238000005245 sintering Methods 0.000 description 6
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 5
- 229910045601 alloy Inorganic materials 0.000 description 5
- 239000000956 alloy Substances 0.000 description 5
- 239000007788 liquid Substances 0.000 description 5
- 239000010936 titanium Substances 0.000 description 5
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 4
- 230000015556 catabolic process Effects 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 239000011148 porous material Substances 0.000 description 4
- 238000007751 thermal spraying Methods 0.000 description 4
- 229910052719 titanium Inorganic materials 0.000 description 4
- 229910000881 Cu alloy Inorganic materials 0.000 description 3
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 3
- 229910052782 aluminium Inorganic materials 0.000 description 3
- 238000003487 electrochemical reaction Methods 0.000 description 3
- 230000003628 erosive effect Effects 0.000 description 3
- 150000002484 inorganic compounds Chemical class 0.000 description 3
- 229910010272 inorganic material Inorganic materials 0.000 description 3
- -1 iron aluminate Chemical class 0.000 description 3
- 239000011777 magnesium Substances 0.000 description 3
- 229910052749 magnesium Inorganic materials 0.000 description 3
- 239000000758 substrate Substances 0.000 description 3
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 239000004411 aluminium Substances 0.000 description 2
- 230000008021 deposition Effects 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 238000007654 immersion Methods 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- LWIHDJKSTIGBAC-UHFFFAOYSA-K tripotassium phosphate Chemical compound [K+].[K+].[K+].[O-]P([O-])([O-])=O LWIHDJKSTIGBAC-UHFFFAOYSA-K 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- 229910001018 Cast iron Inorganic materials 0.000 description 1
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- 229910000861 Mg alloy Inorganic materials 0.000 description 1
- 239000004111 Potassium silicate Substances 0.000 description 1
- 239000004115 Sodium Silicate Substances 0.000 description 1
- 229910001069 Ti alloy Inorganic materials 0.000 description 1
- UQZIWOQVLUASCR-UHFFFAOYSA-N alumane;titanium Chemical compound [AlH3].[Ti] UQZIWOQVLUASCR-UHFFFAOYSA-N 0.000 description 1
- ANBBXQWFNXMHLD-UHFFFAOYSA-N aluminum;sodium;oxygen(2-) Chemical compound [O-2].[O-2].[Na+].[Al+3] ANBBXQWFNXMHLD-UHFFFAOYSA-N 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000013590 bulk material Substances 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000005229 chemical vapour deposition Methods 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 229910052593 corundum Inorganic materials 0.000 description 1
- 239000008367 deionised water Substances 0.000 description 1
- 239000012153 distilled water Substances 0.000 description 1
- 238000010292 electrical insulation Methods 0.000 description 1
- 238000004070 electrodeposition Methods 0.000 description 1
- 229910001385 heavy metal Inorganic materials 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 150000008040 ionic compounds Chemical class 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 150000004767 nitrides Chemical class 0.000 description 1
- 238000005240 physical vapour deposition Methods 0.000 description 1
- 229910000160 potassium phosphate Inorganic materials 0.000 description 1
- 235000011009 potassium phosphates Nutrition 0.000 description 1
- NNHHDJVEYQHLHG-UHFFFAOYSA-N potassium silicate Chemical compound [K+].[K+].[O-][Si]([O-])=O NNHHDJVEYQHLHG-UHFFFAOYSA-N 0.000 description 1
- 229910052913 potassium silicate Inorganic materials 0.000 description 1
- 235000019353 potassium silicate Nutrition 0.000 description 1
- KVOIJEARBNBHHP-UHFFFAOYSA-N potassium;oxido(oxo)alumane Chemical compound [K+].[O-][Al]=O KVOIJEARBNBHHP-UHFFFAOYSA-N 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 239000002243 precursor Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 229910001388 sodium aluminate Inorganic materials 0.000 description 1
- HZJQZHXRILHFBL-UHFFFAOYSA-L sodium oxalate titanium(4+) Chemical compound C(C(=O)[O-])(=O)[O-].[Na+].[Ti+4] HZJQZHXRILHFBL-UHFFFAOYSA-L 0.000 description 1
- 239000001488 sodium phosphate Substances 0.000 description 1
- 229910000162 sodium phosphate Inorganic materials 0.000 description 1
- 235000011008 sodium phosphates Nutrition 0.000 description 1
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 1
- 229910052911 sodium silicate Inorganic materials 0.000 description 1
- 235000019794 sodium silicate Nutrition 0.000 description 1
- 238000003980 solgel method Methods 0.000 description 1
- 229910052596 spinel Inorganic materials 0.000 description 1
- 239000011029 spinel Substances 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 230000003319 supportive effect Effects 0.000 description 1
- RYFMWSXOAZQYPI-UHFFFAOYSA-K trisodium phosphate Chemical compound [Na+].[Na+].[Na+].[O-]P([O-])([O-])=O RYFMWSXOAZQYPI-UHFFFAOYSA-K 0.000 description 1
- 238000010290 vacuum plasma spraying Methods 0.000 description 1
- 229910001845 yogo sapphire Inorganic materials 0.000 description 1
Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D11/00—Electrolytic coating by surface reaction, i.e. forming conversion layers
- C25D11/02—Anodisation
- C25D11/34—Anodisation of metals or alloys not provided for in groups C25D11/04 - C25D11/32
Definitions
- This invention involves an alumina-based ceramic coating on an iron-based or copper-based metallic component for enhanced anti-corrosion and electric insulation.
- Iron-based metallic or copper-based metallic component are widely used for machine, transportation, infrastructure and plant.
- the metallic component often suffers from general corrosion or galvanic corrosion. When electric or magnetic field is involved, the corrosion damaging would accelerate. Addition of anti-corrosion and electric insulation coating can be beneficial for longevity of the component.
- Electric vehicles use electric motors as powertrains which also involve the electric power and magnetic field.
- the bearings, gears and shafts in the drivetrain may need to have electric insulation to avoid electric discharging-induced erosion. Washers and bushes may also need such an electrical insulation to avoid the mentioned electric erosion and to reduce galvanic corrosion.
- the high-power density electric motor need a better cooling system which may however cause corrosion concerns. Therefore, there is a great demand for motor components to have an improved property in terms of anti-corrosion and electric insulation.
- the electric insulation on a bearing can be realized by a ceramic coating deposited on the bearing surface.
- United States patents U.S. Pat. Nos. 9,646,737 and 9,581,203 B2 disclose an insulating coating which is made up of a ceramic layer with a plurality of particles and a plurality of pores between the particles.
- the ceramic layer is selected from a group of powders consisting of an oxide, a combination of oxides, a nitride and a spinel.
- the coating deposition is carried out using a thermal spraying method in dry air atmosphere as shown in patent number WO 2014156206 A1.
- PEA plasma electrolytic aluminating
- PEO plasma electrolytic oxidation
- the PEA process can apply to iron-based alloys and copper.
- the PEA process is a new coating method which combines electrochemical reaction, plasma discharging in a liquid environment, and plasma sintering of in-situ formed ceramic coating materials onto iron-based alloys or copper in the liquid environment.
- the PEA process is significantly different from known ceramic and coating fabrication methods.
- the sintering When someone speaks about ceramic sintering, the sintering is often operated in a furnace to densify a ceramic bulk material, not in a form of a coating [US patent US 2017/0088471 A1].
- the sintering is performed by high temperature heating, not by plasma discharging in liquid.
- a traditional ceramic coating can be prepared in liquid environment through electrochemical [US patent U.S. Pat. No. 4,882,014] or sol-gel methods where again no plasma discharging is involved but sometime furnace sintering as a post-heat treatment is applied [patent US20060147699A1].
- 9,701,177-B2] disclosed a coating method, called plasma electrochemical deposition, which is actually similar to the PEO process that can be applied again only to aluminium, titanium and magnesium.
- the PEA process is developed for components that are not made of aluminum, titanium or magnesium. Therefore, the PEA process is significantly different from the conventional PEO and totally different from vacuum plasma and thermal spraying coating process.
- a modified PEA process is applied on a metallic component that is a bearing, laminate, shaft, gear, bolt, washer, bush or shim made of an iron-based alloy; or wire, hairpin windings made of copper.
- the process is to provide metallic surfaces (i.e., steel, Cu and Cu alloy) with an anticorrosion and electric insulation coating.
- the invention hereby involves an alumina-based ceramic coating which is synthesized using a process similar to the PEA (plasma electrolytic aluminating).
- PEA plasma electrolytic aluminating
- the PEA process reported in prior work is an immersion treatment process where a small cast iron coupon sample is immersed into an electrolyte.
- the coating process in this invention is modified to treat a component on its localized surface, wherein the component is located preferentially outside an electrolyte tank and an aqueous electrolyte is applied onto the localized component surface where the coating is needed.
- the coating has a double layered structure with surface pores.
- the inner layer is formed through electrochemical reaction between the electrolyte and the metallic surface being treated.
- the formed inner layer is made of environmental-friendly inorganic compounds (i.e., iron aluminate, copper aluminate, or aluminum hydroxide depended on the electrolyte used), which is totally different from the metal-based supportive layer (e.g., chromium and nickel) involved in the previously-mentioned thermal spraying technology.
- the outer layer is an alumina-based ceramic comprising alumina (i.e., Al2O3 in chemical formula), aluminium-silicon-oxide, aluminium-titanium-based oxide, or titanium-based oxide, depended on the electrolyte used but independent from the component's material being treated.
- the coating contains no heavy metal in this invention.
- This coating has multifunctionality which includes anti-wear, anti-corrosion and electric insulation.
- the coating surface has some pores which can be sealed obviously by a commercial coating sealing method, if needed, for even better anti-corrosion and electric insulation properties.
- the electrolyte used in this invention contains deionized or distilled water dissolved with 4-40 grams/litre of at least one of sodium aluminate, potassium aluminate, sodium silicate, potassium silicate, sodium phosphate, potassium phosphate, or sodium titanium oxalate.
- the involved metallic component surface is made of steel, copper, or copper alloy.
- the voltage applied during the coating process is 60-600 Volts of a DC or pulsed DC power with a current density of 0.05-5 A/cm2.
- the formed ceramic coating has a double-layer microstructure, wherein the inner layer thickness is 0.5-5 microns, and the outside layer thickness is 5-100 microns.
- the said ceramic coating has anti-wear and anti-corrosion resistances 5-10 times higher than the substrate material without the coating.
- the coating has an electric resistance of 0.1-1 Giga-ohms (G ⁇ ).
- coated components can be used for applications in bearings, laminates, wires, windings, shafts, gears, bolts, washers, bushes and shims.
- FIG. 1 is a schematic illustration of a coating on a metallic substrate.
- a metallic component 1 is connected to a negative electrode (extended from the negative output terminal) of a DC or pulsed DC power supply through providing a liquid electrolyte to complete a closed electric circuit.
- the provision of the electrolyte can be carried out using a spraying method or using a localized immersion method.
- a surface of the component 1 firstly reacts with the electrolyte under a positive bias voltage of 60V-600V to form a thin inorganic compound layer 2.
- the compound layer would dielectrically breakdown when the bias voltage is increased to a certain voltage (preferably beyond 200V up to 600V).
- the coating has a two-layered microstructure.
- the plasma electric discharging under the high bias voltages also generates small pores 4.
- the inner layer thickness can be in a range of 0.5-5 microns and the outer layer thickness can be in a range of 5-100 microns, depended on the treatment time, current density used and the final ending voltage. Longer treatment time, higher current density used and higher ending voltage generate a thicker coating.
- a metallic component made of iron-based steel, or copper or copper alloy is treated using a coating process stated above in paragraph
- Exampled applications of this coating are for bearings, laminates, wires, shafts, gears, washers and bushes in electric motors.
- Electric insulating property of the coating is applied onto inner diameter (ID) or outer diameter (OD) surfaces of bearings or onto shafts and gears especially for avoiding electric erosion problems that may otherwise occur on the bearing rollers and raceways or gear teeth during the service involving electric current and voltage.
- a metallic bearing component made of an iron-based alloy (e.g., steel) has an alumina-based ceramic coating that is deposited on either inner diameter (ID) or outer diameter (OD) or both inner and outer diameter surface(s) of the motor bearing.
- the alumina-based ceramic coating provides the bearing with anti-corrosion and electric insulation.
- the corrosion resistance increases 5-10 times compared with an uncoated bearing.
- the coating has properties of a breakdown voltage in a range of 500 V to 1000 V and an electric resistance in a range of 100 mega-ohms to 300 mega-ohms.
- a metallic laminate component made of electric steels has an alumina-based ceramic coating that is deposited on one side surface or both side surfaces of the laminate.
- the alumina-based ceramic coating provides the laminate with anti-corrosion and electric insulation.
- the corrosion resistance increases 5-10 times compared with an uncoated laminate.
- the coating has properties of a breakdown voltage in a range of 500 V to 1000 V and an electric resistance in a range of 100 mega-ohms to 300 mega-ohms.
- a metallic wire or hairpin-shaped component made of copper has an alumina-based ceramic coating that is deposited on outer surface of the wire or hairpin.
- the alumina-based ceramic coating provides the wire or hairpin with anti-corrosion and electric insulation.
- the corrosion resistance increases 5-10 times compared with an uncoated wire or hairpin.
- the coating has properties of a breakdown voltage in a range of 500 V to 1000 V and an electric resistance in a range of 100 mega-ohms to 300 mega-ohms.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Electrochemistry (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Coating By Spraying Or Casting (AREA)
- Other Surface Treatments For Metallic Materials (AREA)
Abstract
This invention involves an alumina-based coating deposited on a steel or copper metallic component for enhanced anti-corrosion and electric insulation properties. The coated metallic component can be a bearing, laminate, shaft, gear, bolt, washer, bush or shim made of steels; or wire and hairpin winding made of copper.
Description
- This invention involves an alumina-based ceramic coating on an iron-based or copper-based metallic component for enhanced anti-corrosion and electric insulation.
- Iron-based metallic or copper-based metallic component are widely used for machine, transportation, infrastructure and plant. The metallic component often suffers from general corrosion or galvanic corrosion. When electric or magnetic field is involved, the corrosion damaging would accelerate. Addition of anti-corrosion and electric insulation coating can be beneficial for longevity of the component.
- Electric vehicles (EVs) use electric motors as powertrains which also involve the electric power and magnetic field. The bearings, gears and shafts in the drivetrain may need to have electric insulation to avoid electric discharging-induced erosion. Washers and bushes may also need such an electrical insulation to avoid the mentioned electric erosion and to reduce galvanic corrosion. The high-power density electric motor need a better cooling system which may however cause corrosion concerns. Therefore, there is a great demand for motor components to have an improved property in terms of anti-corrosion and electric insulation.
- The electric insulation on a bearing can be realized by a ceramic coating deposited on the bearing surface. United States patents U.S. Pat. Nos. 9,646,737 and 9,581,203 B2 disclose an insulating coating which is made up of a ceramic layer with a plurality of particles and a plurality of pores between the particles. The ceramic layer is selected from a group of powders consisting of an oxide, a combination of oxides, a nitride and a spinel. The coating deposition is carried out using a thermal spraying method in dry air atmosphere as shown in patent number WO 2014156206 A1.
- A new coating technology, called plasma electrolytic aluminating (PEA), has been developing by inventors of this patent for improving corrosion and wear resistance as well as electric insulation. Unlike conventional plasma electrolytic oxidation (PEO) which can only treat aluminum, titanium and magnesium alloys, the PEA process can apply to iron-based alloys and copper. In brief, the PEA process is a new coating method which combines electrochemical reaction, plasma discharging in a liquid environment, and plasma sintering of in-situ formed ceramic coating materials onto iron-based alloys or copper in the liquid environment. The PEA process is significantly different from known ceramic and coating fabrication methods. When someone speaks about ceramic sintering, the sintering is often operated in a furnace to densify a ceramic bulk material, not in a form of a coating [US patent US 2017/0088471 A1]. The sintering is performed by high temperature heating, not by plasma discharging in liquid. A traditional ceramic coating can be prepared in liquid environment through electrochemical [US patent U.S. Pat. No. 4,882,014] or sol-gel methods where again no plasma discharging is involved but sometime furnace sintering as a post-heat treatment is applied [patent US20060147699A1]. When a plasma discharging is relied on for a ceramic coating deposition, it is often that the coating operation is carried out in a vacuum system, e.g., physical vapour deposition or chemical vapour deposition [Canada patent number CA 2850270], or in air environments, e.g., thermal spraying [Canada patent number CA 2883157]. A plasma discharging in a liquid environment for a ceramic coating preparation can be found in plasma electrolytic oxidation (PEO) processes [Surf Coat Technol, 122 (1999) 73-93]. However, the conventional PEO process can be applied only onto engineering materials made of aluminium, titanium and magnesium and their alloys, because the PEO process is a coating conversion process associated with its substrate. A US patent [patent U.S. Pat. No. 9,701,177-B2] disclosed a coating method, called plasma electrochemical deposition, which is actually similar to the PEO process that can be applied again only to aluminium, titanium and magnesium. The PEA process is developed for components that are not made of aluminum, titanium or magnesium. Therefore, the PEA process is significantly different from the conventional PEO and totally different from vacuum plasma and thermal spraying coating process.
- In this invention, a modified PEA process is applied on a metallic component that is a bearing, laminate, shaft, gear, bolt, washer, bush or shim made of an iron-based alloy; or wire, hairpin windings made of copper. The process is to provide metallic surfaces (i.e., steel, Cu and Cu alloy) with an anticorrosion and electric insulation coating.
- The invention hereby involves an alumina-based ceramic coating which is synthesized using a process similar to the PEA (plasma electrolytic aluminating). The PEA process reported in prior work is an immersion treatment process where a small cast iron coupon sample is immersed into an electrolyte. The coating process in this invention is modified to treat a component on its localized surface, wherein the component is located preferentially outside an electrolyte tank and an aqueous electrolyte is applied onto the localized component surface where the coating is needed. The coating has a double layered structure with surface pores. The inner layer is formed through electrochemical reaction between the electrolyte and the metallic surface being treated. The formed inner layer is made of environmental-friendly inorganic compounds (i.e., iron aluminate, copper aluminate, or aluminum hydroxide depended on the electrolyte used), which is totally different from the metal-based supportive layer (e.g., chromium and nickel) involved in the previously-mentioned thermal spraying technology. The outer layer is an alumina-based ceramic comprising alumina (i.e., Al2O3 in chemical formula), aluminium-silicon-oxide, aluminium-titanium-based oxide, or titanium-based oxide, depended on the electrolyte used but independent from the component's material being treated. Thus, the coating contains no heavy metal in this invention. This coating has multifunctionality which includes anti-wear, anti-corrosion and electric insulation. The coating surface has some pores which can be sealed obviously by a commercial coating sealing method, if needed, for even better anti-corrosion and electric insulation properties.
- The electrolyte used in this invention contains deionized or distilled water dissolved with 4-40 grams/litre of at least one of sodium aluminate, potassium aluminate, sodium silicate, potassium silicate, sodium phosphate, potassium phosphate, or sodium titanium oxalate.
- The involved metallic component surface is made of steel, copper, or copper alloy.
- The voltage applied during the coating process is 60-600 Volts of a DC or pulsed DC power with a current density of 0.05-5 A/cm2.
- The formed ceramic coating has a double-layer microstructure, wherein the inner layer thickness is 0.5-5 microns, and the outside layer thickness is 5-100 microns.
- The said ceramic coating has anti-wear and anti-corrosion resistances 5-10 times higher than the substrate material without the coating. The coating has an electric resistance of 0.1-1 Giga-ohms (G□).
- The coated components (or parts) can be used for applications in bearings, laminates, wires, windings, shafts, gears, bolts, washers, bushes and shims.
-
FIG. 1 is a schematic illustration of a coating on a metallic substrate. - Referring to the schematic illustration in
FIG. 1 , ametallic component 1 is connected to a negative electrode (extended from the negative output terminal) of a DC or pulsed DC power supply through providing a liquid electrolyte to complete a closed electric circuit. The provision of the electrolyte can be carried out using a spraying method or using a localized immersion method. A surface of thecomponent 1 firstly reacts with the electrolyte under a positive bias voltage of 60V-600V to form a thininorganic compound layer 2. The compound layer would dielectrically breakdown when the bias voltage is increased to a certain voltage (preferably beyond 200V up to 600V). Under the increased bias voltage, precursors (ionic compounds) in the electrolyte stick onto the top of the inorganiccompound layer surface 2 where a simultaneous process of electrochemical reaction and sintering (by plasma discharging) occurs and forms a hard ceramicouter layer 3. Therefore, the coating has a two-layered microstructure. The plasma electric discharging under the high bias voltages also generatessmall pores 4. The inner layer thickness can be in a range of 0.5-5 microns and the outer layer thickness can be in a range of 5-100 microns, depended on the treatment time, current density used and the final ending voltage. Longer treatment time, higher current density used and higher ending voltage generate a thicker coating. - In accordance with embodiments of this invention, a metallic component made of iron-based steel, or copper or copper alloy is treated using a coating process stated above in paragraph
- . Exampled applications of this coating are for bearings, laminates, wires, shafts, gears, washers and bushes in electric motors. Electric insulating property of the coating is applied onto inner diameter (ID) or outer diameter (OD) surfaces of bearings or onto shafts and gears especially for avoiding electric erosion problems that may otherwise occur on the bearing rollers and raceways or gear teeth during the service involving electric current and voltage.
- In accordance with embodiments of this invention, a metallic bearing component made of an iron-based alloy (e.g., steel) has an alumina-based ceramic coating that is deposited on either inner diameter (ID) or outer diameter (OD) or both inner and outer diameter surface(s) of the motor bearing. The alumina-based ceramic coating provides the bearing with anti-corrosion and electric insulation. The corrosion resistance increases 5-10 times compared with an uncoated bearing. The coating has properties of a breakdown voltage in a range of 500 V to 1000 V and an electric resistance in a range of 100 mega-ohms to 300 mega-ohms.
- In accordance with embodiments of this invention, a metallic laminate component made of electric steels has an alumina-based ceramic coating that is deposited on one side surface or both side surfaces of the laminate. The alumina-based ceramic coating provides the laminate with anti-corrosion and electric insulation. The corrosion resistance increases 5-10 times compared with an uncoated laminate. The coating has properties of a breakdown voltage in a range of 500 V to 1000 V and an electric resistance in a range of 100 mega-ohms to 300 mega-ohms.
- In accordance with embodiments of this invention, a metallic wire or hairpin-shaped component made of copper has an alumina-based ceramic coating that is deposited on outer surface of the wire or hairpin. The alumina-based ceramic coating provides the wire or hairpin with anti-corrosion and electric insulation. The corrosion resistance increases 5-10 times compared with an uncoated wire or hairpin. The coating has properties of a breakdown voltage in a range of 500 V to 1000 V and an electric resistance in a range of 100 mega-ohms to 300 mega-ohms.
Claims (4)
1. A method of depositing an alumina coating on a metallic component, the method comprising:
applying a liquid electrolyte onto a metallic component;
applying a high electric voltage of 200-600 volts onto the metallic component;
depositing an aluminium hydroxide substance onto a surface of the metallic component; and
transforming the aluminium hydroxide substance to an alumina coating on the surface of the metallic component through high voltage electrical discharging in the liquid electrolyte.
2. The method as claimed in claim 1 , wherein the metallic component is a steel bearing.
3. The method as claimed in claim 1 , wherein the metallic component is a steel laminate.
4. The method as claimed in claim 1 , wherein the metallic component is a copper hairpin.
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US17/929,960 Pending US20240076794A1 (en) | 2022-09-06 | 2022-09-06 | Metallic component with a ceramic coating |
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Citations (4)
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US3177408A (en) * | 1961-09-18 | 1965-04-06 | Robert G Mills | Superconductor solenoid with overheat protective structure and circuitry |
US4367101A (en) * | 1981-04-06 | 1983-01-04 | Armco Inc. | Method of providing an anti-stick coating on non-oriented, semi-processed electrical steels to be subjected to a quality anneal |
US4624884A (en) * | 1981-07-01 | 1986-11-25 | Nippondenso Co., Ltd. | Heat radiating insulation for coil |
US20170356075A1 (en) * | 2014-12-24 | 2017-12-14 | Tocalo Co., Ltd | Insulated bearing and bearing coating method |
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2022
- 2022-09-06 US US17/929,960 patent/US20240076794A1/en active Pending
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3177408A (en) * | 1961-09-18 | 1965-04-06 | Robert G Mills | Superconductor solenoid with overheat protective structure and circuitry |
US4367101A (en) * | 1981-04-06 | 1983-01-04 | Armco Inc. | Method of providing an anti-stick coating on non-oriented, semi-processed electrical steels to be subjected to a quality anneal |
US4624884A (en) * | 1981-07-01 | 1986-11-25 | Nippondenso Co., Ltd. | Heat radiating insulation for coil |
US20170356075A1 (en) * | 2014-12-24 | 2017-12-14 | Tocalo Co., Ltd | Insulated bearing and bearing coating method |
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