US2671737A - Aluminum coating process and flux - Google Patents

Aluminum coating process and flux Download PDF

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Publication number
US2671737A
US2671737A US189478A US18947850A US2671737A US 2671737 A US2671737 A US 2671737A US 189478 A US189478 A US 189478A US 18947850 A US18947850 A US 18947850A US 2671737 A US2671737 A US 2671737A
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flux
parts
weight
aluminum
sodium
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US189478A
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Walter E Jominy
John H Olson
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Old Carco LLC
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Chrysler Corp
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    • 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
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/30—Fluxes or coverings on molten baths

Definitions

  • This invention relates to improvements in the formation of aluminum and aluminum alloy coatings on steel and more particularly to an improved process and flux for forming an integral type bond between aluminum or aluminum alloy and steel.
  • One of the main objects of the invention is to provide a flux of this kind which may be applied to the steel to be aluminum coated in the form of a fluent aqueous mixture or suspension of salts, a paste of salts, or a fused mass of salts.
  • Another object of the invention is to provide a flux of this kind which adheres tenaciously to the steel and which is not completely melted, burned on or otherwise injured or removed during dipping in a molten aluminum bath until it has been submerged in the molten aluminum.
  • a further object of the invention is to provide a flux of this kind which readily melts and disappears when an article coated with it is submerged in molten aluminum, in order to expose unoxidized surface portions of the article to the molten aluminum.
  • An additional object of the invention is to provide a flux of this kind which 'provides a substantially integral bond between aluminum and ferrous metal as well as other metals during immersion of such metals in molten aluminum.
  • the metal to be coated preferably ferrous metal or metal of the iron group
  • an oxide reducing and air excluding coating of flux which tenaciously adheres to the metal to be treated and which does not melt or break down until the flux coated metal is immersed in a molten aluminum or aluminum alloy bath.
  • the flux coating formed and applied according to our invention remains intact on the metal to be treated as the metal is projected, in accordance with conventional practice, into the molten aluminum or aluminum alloy bath and that part of the metal being coated immediately adjacent the surface of the bath and yet exposed to the atmosphere above the bath remains coated with flux during immersion of successive adjacent portions of the metal being treated as the latter is slowly projected into the bath.
  • Our improved flux may comprise a fluent aqueous mixture or suspension of certain hereinafter recited salts or it may be produced as a paste of certain salts hereinafter set forth in which a small amount of water is included as a binder. If desired, the flux may be employed in the form of a fused mass of certain salts hereinafter set forth into which the metal to be aluminum coated may be dipped in order to deposit thereon a layer of fused salts which immediately solidify at room temperature.
  • the suspension form of the flux may be produced by mixing in parts of water by weight the following proportions of salts:
  • Sodium fluosilicate NaaSiFs 4to 20 Potassium chloride (KCl) 3 to 5 Sodium chloride (NaCl) 3 to 5 Sodium fluoride (NaF) or cryolite (NasAlFs) 0.8 to 5
  • KCl Potassium chloride
  • NaCl Sodium chloride
  • NaF Sodium fluoride
  • NasAlFs cryolite
  • the work may be inserted in a molten bath of aluminum or aluminum alloy.
  • the aluminum and aluminum alloy bath need not be chemically pure.
  • the immersion of the flux coated work preferably takes place while the bath is at a temperature slightly above its melting point.
  • the paste type flux may be formed by mixing together substantially 15 parts by weight of zinc chloride, 35 parts by weight of sodium chloride, 25 parts by weight of potassium chloride and 25 parts by weight of cryolite. Sufficient water is added to this mixture to bring the paste to a desired consistency such that it may be con- 3 veniently b hed or otherwise applied on to the work. 'I'h; layer of flux paste is allowed to dry thoroughly before the flux paste coated work is immersed in molten aluminum in accordance with the above procedure.
  • the fused salt type flux preferably comprises substantially equal parts of zinc chloride, sodium chloride, potassium chloride and either sodium fluoride or cryolite, the chemical composition of which is set forth above.
  • This mixture of salts is preferably heated to and maintained at approximately 1200 F.
  • the work to be aluminum coated is dipped into the fused salt bath and removed and retained at atmospheric tempera-' tures sufliciently long for the coating of fused salts to solidify.
  • the thus coated work is then immersed in a molten aluminum or aluminum alloy bath in accordance with the above specified procedure.
  • a fluent aqueous flux for conditioning ferrous metal for the reception of an adherent immersion formed coating of aluminum said flux consisting of the following substances as essential constituents and in substantially the proportions given: 100 parts by weight of water, 2 to 40 parts by weight of sodium fluosilicate, 2 to parts by weight of sodium chloride, 2 to 10 parts by weight of potassium chloride and 0.2 to 40 parts by weight of sodium fluoride.
  • a fluent aqueous flux for conditioning ferrous metal for the reception of an adherent immersion formed coating of aluminum said flux consisting of the following substances as essential constituents and in substantially the proportions given: 100 parts by weight of water, 2 to 40 parts by weight of sodium fluosilicate, 2 to 10 parts by weight of sodium chloride, 2 to 10 parts by weight of potassium chloride and 0.2 to 40 parts by weight of sodium aluminum fluoride.
  • a fluent aqueous flux for conditioning ferrous metal for the reception of an adherent immersion formed coating of aluminum said flux consisting o1 the following substances as essential constituents and in substantially the proportions given: 100 parts by weight of water, 2 to 40 parts by weight of sodium fluosilicate, 2 to 10 parts by weight of sodium chloride, 2 to 10 parts by weight of potassium chloride, and 0.2 to 40 parts by weight of a compound selected from the group consisting of sodium fluoride and sodium aluminum fluoride.
  • a fluent aqueous flux for conditioning ferrous metal for the reception of an adherent immersion formed coating 01' aluminum consisting of the following substances as essential constituents and in substantially the proportions given: 100 parts by weight of water, 4 to 20'parts by weight of sodium fluosilicate, 3 to 5 parts by weight of sodium chloride, 3 to 5 parts by weight of potassium chloride, and 0.8 to 5 parts by weight of a compound selected from the group consisting of sodium fluoride and sodium aluminum fluoride.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Coating With Molten Metal (AREA)

Description

/t f G L Patented Mar. 9, 1954 2,671,737 ALUMINUM COATING PROCESS AND FLUX Walter E. Jominy, Detroit, and John H. Olson,
Berkley, Mich., assignors to Chrysler Corporation, Highland Park,
Delaware Mich., a corporation of I No Drawing. Application October 10, 1950,
. Serial No. 189,478
8 Claims. (Cl. 11'751) This invention relates to improvements in the formation of aluminum and aluminum alloy coatings on steel and more particularly to an improved process and flux for forming an integral type bond between aluminum or aluminum alloy and steel.
One of the main objects of the invention is to provide a flux of this kind which may be applied to the steel to be aluminum coated in the form of a fluent aqueous mixture or suspension of salts, a paste of salts, or a fused mass of salts.
Another object of the invention is to provide a flux of this kind which adheres tenaciously to the steel and which is not completely melted, burned on or otherwise injured or removed during dipping in a molten aluminum bath until it has been submerged in the molten aluminum.
A further object of the invention is to provide a flux of this kind which readily melts and disappears when an article coated with it is submerged in molten aluminum, in order to expose unoxidized surface portions of the article to the molten aluminum.
An additional object of the invention is to provide a flux of this kind which 'provides a substantially integral bond between aluminum and ferrous metal as well as other metals during immersion of such metals in molten aluminum.
In practicing the improved aluminum or aluminum alloy coating proces, the metal to be coated, preferably ferrous metal or metal of the iron group, is first coated with an oxide reducing and air excluding coating of flux which tenaciously adheres to the metal to be treated and which does not melt or break down until the flux coated metal is immersed in a molten aluminum or aluminum alloy bath. The flux coating formed and applied according to our invention remains intact on the metal to be treated as the metal is projected, in accordance with conventional practice, into the molten aluminum or aluminum alloy bath and that part of the metal being coated immediately adjacent the surface of the bath and yet exposed to the atmosphere above the bath remains coated with flux during immersion of successive adjacent portions of the metal being treated as the latter is slowly projected into the bath.
Our improved flux may comprise a fluent aqueous mixture or suspension of certain hereinafter recited salts or it may be produced as a paste of certain salts hereinafter set forth in which a small amount of water is included as a binder. If desired, the flux may be employed in the form of a fused mass of certain salts hereinafter set forth into which the metal to be aluminum coated may be dipped in order to deposit thereon a layer of fused salts which immediately solidify at room temperature.
The suspension form of the flux may be produced by mixing in parts of water by weight the following proportions of salts:
Parts by weight The following proportions within the above range are preferred:
Parts by weight Sodium fluosilicate (NaaSiFs) 4to 20 Potassium chloride (KCl) 3 to 5 Sodium chloride (NaCl) 3 to 5 Sodium fluoride (NaF) or cryolite (NasAlFs) 0.8 to 5 In the foregoing formulas, either sodium fluoride or cryolite, a common name for sodium aluminum fluoride, may be employed. The above portions of salts produce a suspension into which the ferrous or other metal parts to be aluminum coated are dipped following cleaning of them and while the flux suspension is heated to slightly under a boiling temperature. When parts are removed from the suspension, they carry with them a continuous film of the suspension which rapidly 'dries because of the temperature to which the suspension is heated and under the influence of the heat imparted from the suspension to the work. As the suspension dries, a substantially air impervious crust-like film of the salts of the suspension is formed on the work in a way which produces an oxide reducing and air excluding envelope about the work.
After the flux coating has dried. the work may be inserted in a molten bath of aluminum or aluminum alloy. The aluminum and aluminum alloy bath need not be chemically pure. The immersion of the flux coated work preferably takes place while the bath is at a temperature slightly above its melting point.
The paste type flux may be formed by mixing together substantially 15 parts by weight of zinc chloride, 35 parts by weight of sodium chloride, 25 parts by weight of potassium chloride and 25 parts by weight of cryolite. Sufficient water is added to this mixture to bring the paste to a desired consistency such that it may be con- 3 veniently b hed or otherwise applied on to the work. 'I'h; layer of flux paste is allowed to dry thoroughly before the flux paste coated work is immersed in molten aluminum in accordance with the above procedure.
The fused salt type flux preferably comprises substantially equal parts of zinc chloride, sodium chloride, potassium chloride and either sodium fluoride or cryolite, the chemical composition of which is set forth above. This mixture of salts is preferably heated to and maintained at approximately 1200 F. The work to be aluminum coated is dipped into the fused salt bath and removed and retained at atmospheric tempera-' tures sufliciently long for the coating of fused salts to solidify. The thus coated work is then immersed in a molten aluminum or aluminum alloy bath in accordance with the above specified procedure.
It is found that work aluminum coated in accordance with the above process, by immersing it in an aluminum or aluminum alloy bath while the surfaces of the work are covered with flux coatings of any of the foregoing types, is characterized by substantially integral bonds between the metal work and the aluminum layer. All of the ingredients of the various formulas of the flux are comparatively inexpensive and readily available.
Although but several specific embodiments of our invention have been described, it is understood that various changes in the materials employed and in the sequence of steps as well as in the temperature and periods of heating may be made without departing from the spirit of our invention.
We claim:
1. A fluent aqueous flux for conditioning ferrous metal for the reception of an adherent immersion formed coating of aluminum, said flux consisting of the following substances as essential constituents and in substantially the proportions given: 100 parts by weight of water, 2 to 40 parts by weight of sodium fluosilicate, 2 to parts by weight of sodium chloride, 2 to 10 parts by weight of potassium chloride and 0.2 to 40 parts by weight of sodium fluoride.
2. A fluent aqueous flux for conditioning ferrous metal for the reception of an adherent immersion formed coating of aluminum, said flux consisting of the following substances as essential constituents and in substantially the proportions given: 100 parts by weight of water, 2 to 40 parts by weight of sodium fluosilicate, 2 to 10 parts by weight of sodium chloride, 2 to 10 parts by weight of potassium chloride and 0.2 to 40 parts by weight of sodium aluminum fluoride.
-3. The process of forming corrosion resisting coatings consisting essentially of aluminum on ferrous metal bodies which consists in coating the ferrous metal with an adherent fluent aqueous flux consisting of the following substances as essential constituents and in substantially the proportions given: 100 parts by weight of water, 2 to 40 parts by weight of sodium fluosilicate, 2 to 10 parts by weight of sodium chloride, 2 to 10 parts by weight of potassium chloride, and 0.2 to 40 parts by weight of a compound selected from the group consisting of sodium fluoride and sodium aluminum fluoride; forming a continuous coating of said flux on said metal which upon drying will provide an oxide reducing and air excluding film of the salts of the flux thereon, drying said coating and immersing said flux coated metal in a molten metal bath consisting essentially of aluminum.
4. A fluent aqueous flux for conditioning ferrous metal for the reception of an adherent immersion formed coating of aluminum, said flux consisting o1 the following substances as essential constituents and in substantially the proportions given: 100 parts by weight of water, 2 to 40 parts by weight of sodium fluosilicate, 2 to 10 parts by weight of sodium chloride, 2 to 10 parts by weight of potassium chloride, and 0.2 to 40 parts by weight of a compound selected from the group consisting of sodium fluoride and sodium aluminum fluoride.
5. A fluent aqueous flux for conditioning ferrous metal for the reception of an adherent immersion formed coating 01' aluminum, said flux consisting of the following substances as essential constituents and in substantially the proportions given: 100 parts by weight of water, 4 to 20'parts by weight of sodium fluosilicate, 3 to 5 parts by weight of sodium chloride, 3 to 5 parts by weight of potassium chloride, and 0.8 to 5 parts by weight of a compound selected from the group consisting of sodium fluoride and sodium aluminum fluoride.
6. The process of forming corrosion resisting coatings consisting essentially of aluminum on ferrous metal bodies which consists in coating the ferrous metal with an adherent fluent aqueous flux consisting of the following substances as essential constituents and in substantially the um aluminum fluoride; forming a continuous 1 coating of said flux on said metal which upon drying will provide an oxide reducing and air excluding film of the salts of the flux thereon, drying said coating and immersing said flux coated metal in a molten metal bath 'consisting essentially of aluminum.
WALTER E. JOMINY. JOHN H. OLSON.
References Cited in the flle of this patent UNITED STATES PATENTS OTHER REFERENCES Handbook of Chemistry & Physics, 27th 136. (1943) pages 456, 457, 458, 459, published by Chemical Rubber Publishing 00., Cleveland, Ohio.

Claims (1)

  1. 3. THE PROCESS OF FOMRING CORROSION RESISTING COATINGS CONSISTING ESSENTIALLY OF ALUMINUM ON FERROUS METAL BODIES WHICH CONSISTS IN COATING THE FERROUS METAL WITH AN ADHERENT FLUENT AQUEOUS FLUX CONSISTING OF THE FOLLOWING SUBSTANCES AS ESSENTIAL CONSTITUENTS AND IN SUBSTANTIALLY THE PROPORTIONS GIVEN: 100 PARTS BY WEIGHT OF WATER, 2 TO 40 PARTS BY WEIGHT OF SODIUM FLUOSILICATE, 2 TO 10 PARTS BY WEIGHT OF SODIUM CHLORIDE, 2 TO 10 PARTS BY WEIGHT OF POTASSIUM CHLRIDE, AND 0.2 TO 40 PARTS BY WEIGHT OF A COMPOUND SELECTED FROM THE GROUP CONSISTING OF SODIUM FLUORIDE AND SODIUM ALUMINUM FLUORIDE; FORMING A CONTINUOUS COATING OF SAID FLUX ON SAID METAL WHICH UPON DRYING WILL PROVIDE AN OXIDE REDUCING AND AIR EXCLUDING FILM OF THE SALTS OF THE FLUX THEREON, DRYING SAID COATING AND IMMERSING SAID FLUX COATED METAL IN A MOLTEN METAL BATH CONSISTING ESSENTIALLY OF ALUMINUM.
US189478A 1950-10-10 1950-10-10 Aluminum coating process and flux Expired - Lifetime US2671737A (en)

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Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2881491A (en) * 1953-03-23 1959-04-14 Chrysler Corp Method of casting aluminum on ferrous base to form duplex structure
US2927043A (en) * 1957-02-20 1960-03-01 Solar Aircraft Co Aluminum coating processes and compositions
US2975084A (en) * 1953-03-23 1961-03-14 Chrysler Corp Flux composition for aluminum casting process and methods for controlling molten flux baths
DE1182500B (en) * 1960-12-06 1964-11-26 Westfaelische Union Ag Flux for the production of aluminum coatings on iron and steel
US3184326A (en) * 1960-06-10 1965-05-18 Republic Steel Corp Coating of iron and steel
US3468770A (en) * 1965-12-22 1969-09-23 Tarun Kumar Ghose Coating of aluminium and/or aluminium alloys on steel surfaces
US3841923A (en) * 1971-06-28 1974-10-15 N Scherbina Flux for accomplishing welding-type electroslag process
US3860438A (en) * 1974-03-11 1975-01-14 Bethlehem Steel Corp Flux and method of coating ferrous article
US5723187A (en) * 1996-06-21 1998-03-03 Ford Global Technologies, Inc. Method of bonding thermally sprayed coating to non-roughened aluminum surfaces

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1653482A (en) * 1922-06-23 1927-12-20 Ig Farbenindustrie Ag Flux applied in soldering aluminum and its alloys
GB314400A (en) * 1928-06-26 1930-07-24 Alloy Welding Processes Ltd Improvements in or relating to the manufacture of saline flux coating compositions for use in soldering or welding
US1941750A (en) * 1930-02-17 1934-01-02 Johansson Erik Harry Eugen Method of thermically coating objects of iron or steel with aluminum or aluminum alloy
US2101553A (en) * 1934-03-05 1937-12-07 Frans Nilsson Coating iron or steel with aluminum or an alloy thereof
US2498199A (en) * 1945-12-03 1950-02-21 Garrett Corp Low melting flux
US2500673A (en) * 1947-05-22 1950-03-14 Parker Rust Proof Co Process of producing a phosphate coating on metals high in aluminum
US2544670A (en) * 1947-08-12 1951-03-13 Gen Motors Corp Method of forming composite aluminum-steel parts by casting aluminum onto steel andbonding thereto

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1653482A (en) * 1922-06-23 1927-12-20 Ig Farbenindustrie Ag Flux applied in soldering aluminum and its alloys
GB314400A (en) * 1928-06-26 1930-07-24 Alloy Welding Processes Ltd Improvements in or relating to the manufacture of saline flux coating compositions for use in soldering or welding
US1941750A (en) * 1930-02-17 1934-01-02 Johansson Erik Harry Eugen Method of thermically coating objects of iron or steel with aluminum or aluminum alloy
US2101553A (en) * 1934-03-05 1937-12-07 Frans Nilsson Coating iron or steel with aluminum or an alloy thereof
US2498199A (en) * 1945-12-03 1950-02-21 Garrett Corp Low melting flux
US2500673A (en) * 1947-05-22 1950-03-14 Parker Rust Proof Co Process of producing a phosphate coating on metals high in aluminum
US2544670A (en) * 1947-08-12 1951-03-13 Gen Motors Corp Method of forming composite aluminum-steel parts by casting aluminum onto steel andbonding thereto

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2881491A (en) * 1953-03-23 1959-04-14 Chrysler Corp Method of casting aluminum on ferrous base to form duplex structure
US2975084A (en) * 1953-03-23 1961-03-14 Chrysler Corp Flux composition for aluminum casting process and methods for controlling molten flux baths
US2927043A (en) * 1957-02-20 1960-03-01 Solar Aircraft Co Aluminum coating processes and compositions
US3184326A (en) * 1960-06-10 1965-05-18 Republic Steel Corp Coating of iron and steel
DE1182500B (en) * 1960-12-06 1964-11-26 Westfaelische Union Ag Flux for the production of aluminum coatings on iron and steel
US3468770A (en) * 1965-12-22 1969-09-23 Tarun Kumar Ghose Coating of aluminium and/or aluminium alloys on steel surfaces
US3841923A (en) * 1971-06-28 1974-10-15 N Scherbina Flux for accomplishing welding-type electroslag process
US3860438A (en) * 1974-03-11 1975-01-14 Bethlehem Steel Corp Flux and method of coating ferrous article
US5723187A (en) * 1996-06-21 1998-03-03 Ford Global Technologies, Inc. Method of bonding thermally sprayed coating to non-roughened aluminum surfaces

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