WO2015154214A1 - Procédé de fabrication d'un revêtement résistant à la corrosion et d'aspect brillant pour pièce de fabrication métallique légère - Google Patents

Procédé de fabrication d'un revêtement résistant à la corrosion et d'aspect brillant pour pièce de fabrication métallique légère Download PDF

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Publication number
WO2015154214A1
WO2015154214A1 PCT/CN2014/074878 CN2014074878W WO2015154214A1 WO 2015154214 A1 WO2015154214 A1 WO 2015154214A1 CN 2014074878 W CN2014074878 W CN 2014074878W WO 2015154214 A1 WO2015154214 A1 WO 2015154214A1
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Prior art keywords
primer coating
coating
thickness
onto
layer
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PCT/CN2014/074878
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English (en)
Inventor
Ming Liu
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GM Global Technology Operations LLC
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Publication date
Application filed by GM Global Technology Operations LLC filed Critical GM Global Technology Operations LLC
Priority to PCT/CN2014/074878 priority Critical patent/WO2015154214A1/fr
Priority to CN201410666394.4A priority patent/CN104975292B/zh
Priority to US14/670,819 priority patent/US9797036B2/en
Priority to DE102015105139.7A priority patent/DE102015105139A1/de
Publication of WO2015154214A1 publication Critical patent/WO2015154214A1/fr

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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
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/34—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates
    • C23C28/345—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D7/00—Electroplating characterised by the article coated
    • 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
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
    • C23C14/14—Metallic material, boron or silicon
    • C23C14/16—Metallic material, boron or silicon on metallic substrates or on substrates of boron or silicon
    • 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
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • 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
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/32—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer
    • 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
    • C25D11/026—Anodisation with spark discharge
    • 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
    • C25D11/04—Anodisation of aluminium or alloys based thereon
    • C25D11/18—After-treatment, e.g. pore-sealing
    • C25D11/20—Electrolytic after-treatment
    • 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
    • C25D11/04—Anodisation of aluminium or alloys based thereon
    • C25D11/18—After-treatment, e.g. pore-sealing
    • C25D11/24—Chemical after-treatment
    • C25D11/246—Chemical after-treatment for sealing layers
    • 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
    • C25D11/26—Anodisation of refractory metals or alloys based thereon
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D13/00—Electrophoretic coating characterised by the process
    • C25D13/22—Servicing or operating apparatus or multistep processes
    • 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

  • the present disclosure relates to coatings and methods of applying surface treatments for increased corrosion resistance of metals and alloys susceptible to corrosion.
  • Alloy road wheels with high magnesium or aluminum content are not uncommon on specialty and racing vehicles.
  • the use of the wheels in less expensive passenger vehicles has, however, been limited to a few production sports cars.
  • galvanic corrosion is a design consideration in high magnesium content alloy wheels when mated to steel or cast iron wheel hub and brake components. Frequently, these components may spend much of their service life in damp or wet conditions, unfortunately often with road salts, which accelerates the galvanic corrosion reactions.
  • Various coatings have been applied to light metal workpieces and substrates, such as alloy wheels, for increasing corrosion protection, but they have had many drawbacks. For example, workpieces having only thick oxide layers formed thereon have been used, butwere often brittle and prone to cracking.
  • wheels may be provided as two-component assemblies having inner and outer portions, with the inner portion galvanically isolating the outer portion from the steel or cast iron wheel hub and brake components. However, such two component assemblies may not always be desirable.
  • the present teachings provide a light metal workpiece with enhanced surface protection.
  • the workpiece comprises a metal or alloy matrix, such as magnesium, having an exposed surface with a corrosion resistance basecoat applied onto at least a portion of the exposed surface, and a protective topcoat applied onto at least a portion of the corrosion resistance basecoat.
  • the corrosion resistance basecoat may include a pretreatment layer and a first primer coating applied onto at least a portion of the pretreatment layer.
  • the protective topcoat may include a second primer coating applied onto at least a portion of the first primer coating and a sputtered metallic film applied onto at least a portion of the second primer coating using a physical vapor deposition technique.
  • a clear coat layer may be applied onto at least a portion of the metallic film.
  • the present teachings provide a magnesium metal wheel comprising a magnesium metal matrix having an exposed surface.
  • a magnesium oxide ceramic layer may be formed in at least a portion of the exposed surface.
  • a first primer coating may be applied onto at least a portion of the magnesium oxide ceramic layer.
  • a second primer coating may be applied onto at least a portion of the first primer coating.
  • a sputtered metallic film may be deposited onto at least a portion of the second primer coating using a physical vapor deposition technique.
  • a clear coat layer may then be applied onto at least a portion of the metallic film.
  • the sputtered metallic film may bedeposited having a thickness of from about 5 nm to about 15nm.
  • each of the first primer coating and the second primer coating comprises at least one of an electrostatic coating and a powder material coating.
  • the present teachings include a method of providing an enhanced surface coating on a metal or alloy substrate.
  • the method comprises providing a metal or alloy substrate having an exposed surface.
  • a corrosion resistance basecoat may be formed onto at least a portion of the exposed surface.
  • the corrosion resistance basecoat may be formed by generating an oxide layer on the exposed surface of the substrate and applying a first primer coating onto the oxide layer.
  • a protective topcoat may be formed onto at least a portion of the corrosion resistance basecoat.
  • the method of forming the protective topcoat may include applying a second primer coating onto at least a portion of the first primer coating and depositing a sputtered metallic film onto the second primer coating using a physical vapor deposition technique.
  • the sputtered metallic film may be deposited having a thickness of from about 5 nm to about 15nm.
  • the method may further include applying a clear coat layer over at least a portion of the metallic film.
  • each of the first primer coating and the second primer coating comprises at least one of an electrostatic coating and a powder material coating.
  • Figure 1 is a front plan view of an exemplary wheel assembly according to various aspects of the present disclosure
  • Figure 2 is a cross-sectional view of the wheel assembly taken along the line 2-2 of Figure 1 ;
  • Figure 3 is a simplified diagram representationillustrating various coatings that can be applied to a metal matrix according to various aspects of the present disclosure.
  • the figures set forth herein are intended to exemplify the general characteristics of materials, methods, and devices among those of the present technology, for the purpose of the description of certain aspects. These figures may not precisely reflect the characteristics of any given aspect, and are not necessarily intended to define or limit specific embodiments within the scope of this technology. Further, certain aspects may incorporate features from a combination of figures.
  • the word "include,” and its variants, is intended to be non-limiting, such that recitation of items in a list is not to the exclusion of other like items that may also be useful in the materials, compositions, devices, and methods of this technology.
  • the terms “can” and “may” and their variants are intended to be non-limiting, such that recitation that an embodiment can or may comprise certain elements or features does not exclude other embodiments of the present technology that do not contain those elements or features.
  • Spatially relative terms such as “inner,” “outer,” “beneath, “”below,””lower,””above,””upper,””on,” and their variants, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s). Spatially relative terms may encompass different orientations of the device in use or operation. As used herein, when a coating, layer, or material is “applied onto,” “applied over,””formed on,” “deposited on,” etc. another substrate or item, the added coating, layer, or material may be applied, formed, deposited on an entirety of the substrate or item, or on at least a portion of the substrate or item.
  • the present technology generally relates to enhanced surface coatings for light metal workpieces and valve metals.
  • the terrri'valve metal is used to refer to a metal or metal alloy that can self-grow nano-porous oxide films.
  • the resultant oxide layer formed on a valve metal may well provide some degree of corrosion protection, as it constitutes a physical barrier between the metal and a corrosive environment. However, it may not be aesthetically pleasing, and may not provide proper corrosion resistance for light metal workpieces, such as wheels.
  • Example valve metals useful with the present technology include aluminum, magnesium, titanium, zirconium, hafnium, chromium, cobalt, molybdenum, vanadium, tantalum, and mixtures and alloys thereof. As is known in the art, valve metals may exhibit electrical rectifying behavior in an electrolytic cell and, under a given applied current, will sustain a higher potential when anodically charged than when cathodically charged.
  • the present teachings provide a light metal workpiece, such as a valve metal or metal alloy, with enhanced surface protection.
  • the light metal workpiece may be a wheel 10, such as an aluminum, magnesium, or alloy wheel.
  • the technology of the present disclosure can generally be used with any wheel design, or any other workpiece or component envisioned to be made from a valve metal that may have an exposed surface subject to a corrosive environment.
  • the wheel 10 may generally be a unitary member or optionally be provided with a center portion 12 coupled with an outer wheel portion 14, as shown.
  • the outer wheel portion 14 may include a rim 16 and may also include one or more spokes 18 extending from the rim 16 in a generally radial direction toward the center wheel portion 12.
  • the wheel portion 12 may include a center opening 20 suitable for a wheel cap (not shown) and may define one or more lug holes 22 useful for attaching the wheel 10 to a vehicle.
  • the wheel 10 may have an inboard side 10a and an outboard side 10b.
  • the inboard side 10a generally indicates the side of the wheel 10 that faces the vehicle
  • the outboard side 10b generally indicates the side of the wheel 10 that faces away from the vehicle and visible when the wheel 10 is attached to the vehicle.
  • the wheel 10 or other light metal workpiece comprises a metal or alloy matrix having an exposed surface.
  • FIG. 3 is a simplified diagram representation illustrating various coatings that can be applied to a portion or an entirety of an exposed surface of a metal matrix according to various aspects of the present disclosure.
  • the coatings and treatments discussed herein may be applied to the entire workpiece, or portions thereof.
  • both the inboard side 10a and the outboard side 10b of a wheel may be subjected to methods of the present teachings that apply enhanced corrosion protection coatings, but it may be desirable to only apply certain coating(s) or layer(s) to the visible outboard side 10b.
  • Reference number 30 of FIG. 3 generally indicates the metal matrix, which initially has an exposed surface 30a.
  • the light metal workpiece having the exposed metal matrix surface 30a may undergo various cleaning processes as is known in the art, including degreasing, descaling, neutralization, and similar washing processes.
  • a corrosion resistance basecoat 32 may be applied to the metal matrix, followed by a protective and appearance enhancing topcoat 40.
  • a pretreatment layer 34 may be applied or formed on the exposed surface 30a.
  • the pretreatment layer 34 may be acorrosion resistant oxide layerformed in the exposed surface 30a using a micro-arc oxidation or plasma electrolytic technique.
  • a first primer coating 36 may be applied onto the oxide layer 34 and may be configured to seal the oxide layer 34.
  • a second primer coating 42 may then be applied onto the first primer coating 36.
  • the first primer coating 36 and the second primer coating 42 may include at least one of an electrostatic coating and a powder material coating.
  • a metallic film 44 may be applied onto the second primer coating 42 to impart a highly reflective, finished look.
  • Aclear coat 46 may then be applied over at least a portion the metallic film 44 (for example, the outboard side 10b) as a final protective barrier.
  • the clear coat 46 may include one or more coatings of a suitable material that imparts a desired color/tint, shine, and/or gloss to the workpiece.
  • micro-arc oxidationtechniques (“MAO"), sometimes also referred to as plasma electrolytic oxidation (“PEO”), spark anodizing, discharge anodizing, or other combinations of these terms, may involve the use of various electrolytes to work in an electrolytic cell and that help generate a porous oxide layer, or porous oxide ceramic layer, at the exposed surface of metal matrix.
  • the oxide layer or oxide ceramic layer may be formed using MAO or PEO techniques to yield a layer of alumina or an alumina ceramic, the composition of which may vary based on the electrolyte and other materials present therein.
  • the oxide layer or ceramic oxide layer may be formed using MAO or PEO techniques to yield a layer of magnesia or magnesium oxide ceramic.
  • MAO and PEO processes There are many patented and commercial variants of the MAO and PEO processes, including those described inU.S. Pat. Nos. 3,293, 158; 5,792,335; 6,365,028; 6,896,785; and U.S. Patent Application Serial No. 13/262,779, published as U.S. Pub. Pat. App. No. 2012/0031765, each of which is incorporated herein by reference in its entirety.
  • the MAO or PEO process may be performed using a silicate-based electrolyte that may include sodium silicate, potassium hydroxide, and potassium fluoride.
  • the presence of micropores and/or cracks on the surface of MAO or PEO coatings can be considered as both an "opportunity”and a “potential weakness.”By way of an "opportunity,” the presence of a porous outer layer in MAO or PEO coatings can significantly improve the mechanical interlocking effect, the bonding area, and stress distribution, resulting in higher bond strength.
  • the presence of a higher pore density on the surface of the MAO or PEO coatings increases the effective surface area and thus the tendency of a corrosive medium to adsorb and concentrate into these pores.
  • the pore density, distribution of pores and interconnectivity of the pores with the remainder of the substrate can be important factors.
  • the oxide layer 32 or ceramic layer may be generated or formed having a controlled and substantially uniform porosity of from about 0.1 pm to about 5 pm, from about 1 pmto about 3 pm, or from about 0.1 pm to about 1 pm.
  • the oxide layer 32 may be generated or formed having a substantially uniform thickness of from about 2 m to about 30 pm, from about 4 pm to about 25 pm, or from about 5 pm to about 20 pm.
  • the present disclosure applies a first primer coating over the oxide layer.
  • the first primer coating may be an electrostatic coating layer, or electrostatic layer, applied onto the oxide layer using an electrocoating technique (“e-coating" or electrophoresis coating) that is configured to seal the oxide layer and provide for increased adhesion of optional additional layers applied thereon.
  • the first primer coating may include a powder material coating.
  • the workpiece Prior to the application of the first primer coating, the workpiece may optionally be washed or immersed in deionized water.
  • sealer systems that may be used in conjunction with the MAO and PEO processes, and theymay include a wide variety of polymers and resins, including but not limited to, fluoropolymers, acrylic, epoxy, polyester, polysiloxanes, and polyvinylidene fluoride (PVDF). These materials may be applied in the form of electrostatically sprayed coatings, by electrophoretic deposition, or by known dipping or wet spraying techniques.
  • an epoxy resin may be used, for example, EPOXY RESIN KATAPHORESIS COATING (EED-060M), commercially available from Unires, or its constituent companyTianjin Youli Chemical Co., Ltd. of Tianjin, China.
  • EED-060M EPOXY RESIN KATAPHORESIS COATING
  • the first primer coating will not contain a significant amount of any chemically active agent therein.
  • the e-coating treatment process may take place from 0 to about 3 minutes using a voltage of between about 160V to about 220V, and cured at a temperature of from about 160°C to about 180°C for a curing time of from about 20 to about 30 minutes.
  • the first primer coating may be ane-coating or powder material coating applied having a substantially uniform thickness of from about 1 ⁇ to about 200 pm, or from about 50 m to about 150 pm, or from about 70 m to about 130 m, or from about 80 m to about 120 pm, or about 100 m.
  • the approaches adopted with the present teachings include applying the first primer coating on the oxide layer within less than about 30 hours, and preferably less than about 24 hours, less than about 20 hours, or less than about 16 hours after generating or forming the oxide or ceramic oxide layer.
  • the first primer coating may be a powdered coating material.
  • Powder coating materials useful hereinas the first primer coating may include thermoplastic or reactive polymers commonly used in the art that are typically solid at room temperature. Most powders are reactive one-component systems that liquefy, flow, and then crosslink as a result of treatment with heat. Common polymers that may be used as powder coating materials include polyester, polyurethane, polyester-epoxy (known as hybrid), straight epoxy (fusion bonded epoxy), and acrylics.
  • the method of applying the powder material coating can include electrostatically spraying a wet black resin powder onto the oxide layer of a heated substrate, the resin powder being delivered at a voltage of from about 40kV to about 50kV, or about 45 kV, and a current of from about 0.4A to about 0.6A, or about 0.5A.
  • the methods of the present teachings further include curing and condensing any powder coating layer by placing the workpiece or substrate in a heated environment at a temperature of from about 180°C to about 200°C, or about 190°C, for a time period of from about 15 minutes to about 25 minutes, or about 20 minutes.
  • a wide range of materials and methods for encapsulation are commercially available that provide for a variety of strategies to create the degree of durability and corrosion resistance.
  • the approaches adopted with the present teachings include applying a protective topcoat 40 that may include a second primer coating 42 onto the first primer coating 36.
  • the entire method may be performed in a single assembly line.
  • the corrosion resistance basecoat layer may be applied in a first assembly, and the protective topcoat may be applied in a second assembly.
  • the second primer coating may be an e-coating or powder material coating applied having a substantially uniform thickness of from about 1 pm to about 200 pm, or from about 50 pm to about 150 pm, or from about 70 pm to about 130 pm, or from about 80 pm to about 120 pm, or about 100 pm.
  • the first primer coating can be applied onto the oxide layer having a first thickness
  • the second primer coating can be applied onto the first primercoating having a second thickness.
  • the first thickness may be substantially equal to or slightly less than the second thickness.
  • the second primer coating may be the same material as the first primer coating, or it may be a different material from the first primer coating.
  • Both primer coatings may be e-coatings, both primer coatings may be powder coating layers, or one of the primer coatings may be an e-coating, while the other primer coating may be a powder material coating.
  • first primer coating is an electrocoating and the second primer coating is a powder material coating, it may be beneficial to have a powder material coating having a thickness much greater than the electrocoating in order to provide increased corrosion protection.
  • the approaches adopted with the present teachings may include applying the second layer having a second thickness of from about 1.5 to about 10 times greater than the first thickness of the first coating.
  • a first primer coating having a thickness of about 15 pm may be used with a second primer coating having a thickness of from about 25 pm to about 150 pm.
  • the methods of the present teachings may include heating the workpiece or substrate having the first primer coating to a temperature of from about 80°C to about 100°C prior to applying the second primer coating.
  • the second primer coating may include a powder coating mainly containing a large portion of polyurethane. It may include, for example, a TIGER DRYLAC® powder coating "wet black" 049/80036, having a high gloss, commercially available from TIGER Coatings GmbH & Co, of Austria.
  • a variety of depositing methods may be employed to apply the metal compositions that form the metal layer or metal film 44 in the topcoat portion 40.
  • One preferred method of depositing the metalfilm44 onto the second primer coating 42 iswith sputter deposition techniques.
  • Sputter deposition is an ion-assisted, physical vapor deposition (PVD) technique of depositing thin films by sputtering. This typically involves ejecting material from a "target” that is a source onto a "substrate” such as the primer coating on a workpiece.
  • the physical vapor deposition may be open air plasma assisted physical vapor deposition or ion beam assisted physical vapor deposition.
  • Preferred metals for the sputtered metal film 44 include those that impart a shiny metallic appearance, for example, chromium (Cr) or compounds of Cr, such as chromium nitride (CrN); or nickel (Ni) or compounds of Ni.
  • the metal film composition may comprise mixtures of the above identified metals
  • One exemplary apparatus may include a deposition chamber and one or more electron guns for deposition of the metal film.
  • the apparatus may be operated in an ultra-high vacuum.
  • the substrate to be coated with the metal film may be first placed in a chamber and the pressure is lowered.
  • a first crucible in the chamber may hold the metal to be deposited.
  • a second metal maybe held by a second crucible, which is deposited over the first layer, forming a second layer.
  • Another option available may be to deposit a combination of metals simultaneously.
  • Metals may be deposited on the second primer coating at a rate of about 0.10 nm/s to a thickness of greater than about 1 nm and less than about50 nm, which can observed by thickness monitors known in the art.
  • the metal film may have be deposited onto the second primer coating at ultra-low thicknesses of less than about50 nm, less than about 40 nm, or about 30 nm or about 25 nm.
  • it may be possible to coat a very thin layer, for example, an ultra-thin layer on the order of from about 1 nm to about 20 nm, from about 5 nm to about 15 nm, or about 10 nm, still achieving good surface coverage, substantially uniform coverage, and good adhesion. Accordingly, the use of PVD allows the metal film to be deposited on the second primer coating substrate very smoothly, evenly, and in a thin layer.
  • PVD methods mayinclude magnetron sputtering, where a target (the second primer coating 42) is bombarded with a sputter gun in an argon ion atmosphere, while the substrate is charged.
  • the sputter gun forms a plasma of metal particles and argon ions that transfer by momentum to coat the substrate.
  • Still other methods of applying the metal film 44 may include electron beam evaporation, where the substrate is contained in a vacuum chamber (from between about 10 "3 to 10 "4 Torr or about 1.3 x 10 "1 Pa to 1.3 x 10 "2 Pa) and a metal evaporant is heated by a charged electron beam, where it evaporates and then condenses on the target substrate.
  • the metal film 44 may also be applied by electroplating (e.g. electrolytic deposition), electroless deposition/plating, or pulse laser deposition. lt is also envisioned that, depending on the material of the second primer coating layer, the metal film may also be applied by electroplating (e.g. electrolytic deposition), or pulse laser deposition.

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  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Electrochemistry (AREA)
  • Mechanical Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)

Abstract

La présente invention concerne une pièce de fabrication métallique, telle qu'une roue, et un procédé de production d'un revêtement de surface amélioré sur un substrat en métal ou en alliage. Le procédé comprend la fourniture d'un substrat en métal ou en alliage, tel que du magnésium, ayant une surface exposée. Une couche de base de résistance à la corrosion est formée sur au moins une partie du substrat, comprenant la génération d'une couche d'oxyde sur la surface exposée du substrat, et l'application d'une première couche primaire sur au moins une partie de la couche d'oxyde. Le procédé comprend la formation d'une couche de finition sur au moins une partie de la couche de base. La formation de la couche de finition comprend l'application d'une deuxième couche primaire sur au moins une partie de la première couche primaire et le dépôt d'un film métallique déposé par pulvérisation cathodique sur la deuxième couche primaire au moyen d'une technique de dépôt physique en phase vapeur. Une couche de revêtement transparente peut être appliquée sur le film métallique.
PCT/CN2014/074878 2014-04-08 2014-04-08 Procédé de fabrication d'un revêtement résistant à la corrosion et d'aspect brillant pour pièce de fabrication métallique légère WO2015154214A1 (fr)

Priority Applications (4)

Application Number Priority Date Filing Date Title
PCT/CN2014/074878 WO2015154214A1 (fr) 2014-04-08 2014-04-08 Procédé de fabrication d'un revêtement résistant à la corrosion et d'aspect brillant pour pièce de fabrication métallique légère
CN201410666394.4A CN104975292B (zh) 2014-04-08 2014-11-20 制造用于轻金属工件的抗腐蚀且有光泽的外观涂层的方法
US14/670,819 US9797036B2 (en) 2014-04-08 2015-03-27 Method of making corrosion resistant and glossy appearance coating for light metal workpiece
DE102015105139.7A DE102015105139A1 (de) 2014-04-08 2015-04-02 Verfahren zum Herstellen einer korrosionsbeständigen und glänzend erscheinenden Beschichtung für ein Leichtmetallwerkstück

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PCT/CN2014/074878 WO2015154214A1 (fr) 2014-04-08 2014-04-08 Procédé de fabrication d'un revêtement résistant à la corrosion et d'aspect brillant pour pièce de fabrication métallique légère

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US9797036B2 (en) 2014-04-08 2017-10-24 GM Global Technology Operations LLC Method of making corrosion resistant and glossy appearance coating for light metal workpiece
CN108546910A (zh) * 2018-03-15 2018-09-18 中信戴卡股份有限公司 一种轮毂耐老化镀膜及形成该保护膜的方法
EP3491169A4 (fr) * 2016-10-26 2020-05-06 Hewlett-Packard Development Company, L.P. Revêtement de substrats en alliage
CN113088966A (zh) * 2021-03-31 2021-07-09 中国兵器科学研究院宁波分院 一种镁合金复合涂层及其制备方法
US20220323994A1 (en) * 2019-12-10 2022-10-13 The Boeing Company Systems and methods of forming a fluid barrier

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CN101370961A (zh) * 2006-04-19 2009-02-18 罗帕尔股份公司 用于制造防腐蚀和高光泽基底的方法
US20090321210A1 (en) * 2008-06-26 2009-12-31 Gm Global Technology Operations, Inc. Coatings for clutch plates
US20110064941A1 (en) * 2009-09-11 2011-03-17 Gm Global Technology Operations, Inc. Corrosion inhibitors in breakable microcapsules to passivate scratched metals
US20110062036A1 (en) * 2009-09-11 2011-03-17 Gm Global Technology Operations, Inc. Frangible capsule-in-capsule chemical delivery systems and methods of fabrication

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US20050175785A1 (en) * 2004-02-07 2005-08-11 Dr. Ing. H.C. F. Porsche Aktiengesellschaft Method for the manufacture of corrosion resistant and decorative coatings and laminated systems for metal substrates
CN101370961A (zh) * 2006-04-19 2009-02-18 罗帕尔股份公司 用于制造防腐蚀和高光泽基底的方法
US20090321210A1 (en) * 2008-06-26 2009-12-31 Gm Global Technology Operations, Inc. Coatings for clutch plates
US20110064941A1 (en) * 2009-09-11 2011-03-17 Gm Global Technology Operations, Inc. Corrosion inhibitors in breakable microcapsules to passivate scratched metals
US20110062036A1 (en) * 2009-09-11 2011-03-17 Gm Global Technology Operations, Inc. Frangible capsule-in-capsule chemical delivery systems and methods of fabrication

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9797036B2 (en) 2014-04-08 2017-10-24 GM Global Technology Operations LLC Method of making corrosion resistant and glossy appearance coating for light metal workpiece
EP3491169A4 (fr) * 2016-10-26 2020-05-06 Hewlett-Packard Development Company, L.P. Revêtement de substrats en alliage
CN108546910A (zh) * 2018-03-15 2018-09-18 中信戴卡股份有限公司 一种轮毂耐老化镀膜及形成该保护膜的方法
US20220323994A1 (en) * 2019-12-10 2022-10-13 The Boeing Company Systems and methods of forming a fluid barrier
CN113088966A (zh) * 2021-03-31 2021-07-09 中国兵器科学研究院宁波分院 一种镁合金复合涂层及其制备方法

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