JPH0260760B2 - - Google Patents

Description

[Detailed description of the invention]

The present invention relates to a composite electrodeposited coating comprising a metal matrix electrodeposited from a plating bath containing particles substantially insoluble in the plating bath, the matrix containing particles simultaneously deposited from the plating bath. Such coatings can be applied by electrolytic or electroless methods. It has been proposed to use various metals as the matrix, such as nickel and cobalt, and it has been proposed to use various particles, such as silicon carbide, chromium carbide and graphite. One object of the present invention is to provide a coating with a high degree of resistance to oxygen and/or corrosion at high temperatures, for example in sulfur-containing environments. Such conditions occur in jet or rocket engines. Yet another object of the invention is to provide a resistive coating that remains substantially unaffected by thermal cycling. In accordance with the invention, a composite electrodeposited coating is comprised of a metal matrix electrodeposited from a plating bath, the metal matrix containing some or all of the particles substantially insoluble in the bath, co-electrodeposited from the bath. and the particles are comprised of a chromium-containing material, an aluminum-containing material, and an oxide of a rare earth metal and/or an oxide of a group metal of the periodic table, the chromium-containing material being chromium or a chromium alloy. , the aluminum compound is aluminum or an aluminum alloy, and the chromium-containing material and the aluminum-containing material are from a chromium-aluminum powder alloy and a chromium-aluminum powder alloy mixed with chromium and/or aluminum. It is characterized by being selectable. Preferably the metal matrix consists of nickel or cobalt and the coating is applied to a suitable substrate such as steel,
It can be used to coat substrates such as high temperature creep resistant nickel alloys, non-ferrous light alloys and non-metallic materials with conductive layers on the outside. The oxides present in the coating may be oxides of zirconium, titanium or hafnium and preferably consist of "lime-stabilized" zirconia. The oxide may constitute 0.01-5% of the coating, preferably about 2% by weight, and may be present in a particle size range of 0-10 microns. Chromium present in the coating is 40% by weight of the coating
It can account for up to 10%, preferably 10-20%, for example 15%. Aluminum present in the coating up to 25% by weight of the coating, preferably 10-20%
may be occupied. The particles may have a diameter of up to 10 microns, preferably with the majority falling in the 1-2 micron range. The present invention involves electrodepositing a metal matrix from a plating bath, co-electrodepositing a portion of particles substantially insoluble in the plating bath, and then pack aluminizing at high temperatures to diffuse the aluminum to the surface of the coating. In particular, a method of manufacturing a composite electrodeposited coating is provided. After adhesion, the coating is heated at 1000℃ during use, for example.
Further heat treatment can be carried out by holding for a certain period of time. It has been found that a layer of aluminum oxide is formed on the surface by diffusing and oxidizing aluminum atoms into the surface. This process is carried out until the surface is coated. After the first oxide layer coats the surface, aluminum can be diffused through the oxide and further reacted with oxygen at the surface, or oxygen can be diffused through the oxide and reacted with aluminum for further oxidation at the metal-oxide interface. It is thought that by forming a compound, it is possible to further form only an oxide. A further possibility is that both mechanisms work, and that the new oxide also
It is formed within an already existing oxide. Generally, if metal atoms diffuse outward through an oxide, vacancies will be left behind. In the case of known castings, over time, vacancies usually collect at the interface between the metal and the oxide, forming voids, and the oxide becomes host in some places. It is thought that it will only adhere to metal. Additionally, the oxide formed has a larger volume than the parent metal from which it was formed, and therefore compressive stresses will be created in the growing oxide layer. This may result in a complex stress state at the oxide-metal interface, which is thought to consist primarily of shear stresses and lateral stresses that act to pull the oxide away from the metal. The net result of these stresses together with the lack of adhesion at the interface will be that the oxide will flake off and new metal will be exposed to hot gases. This process occurs repeatedly, resulting in gradual loss of metal. The problem that would arise if oxide exfoliation did not occur is that the oxide would simply thicken over time, weakening the part as the metal cross section decreases. One way to solve these problems is to reduce the rate at which oxygen and metals diffuse through the oxide and provide a means to eliminate vacancies and thus prevent their formation. It is in this way that the inclusion of thermodynamically stable and chemically stable oxide particles in an oxidizing atmosphere significantly improves the adhesion of aluminum oxide to the matrix metal at the coating surface. It is believed that the effect is achieved in three ways, either alone or in combination. One of them is "stress relief"
The mechanism is that the presence of oxide particles on the coating surface causes the growing oxide film to grow laterally, thereby relieving any stress in the film. This provides starting points for film growth (dead spots). The second is the "vacancy sink" mechanism, in which the vacancies left behind by aluminum atoms that have diffused to the surface and reacted with oxygen are at least partially filled by oxide molecules, resulting in The oxide particles undergo rearrangement so that they occupy vacancies that effectively "diffuse" through the matrix. The third is simply reducing the diffusion coefficient of metal ions or oxygen atoms or both diffusing through the surface of the growing oxide layer. The above adhesion enhancement will be described in relation to aluminum and its oxides. However, the description also applies to chromium and its oxides, and therefore also to aluminum-chromium alloys and oxides of both. In fact, increasing the relative amount of aluminum results in more aluminum oxide in the outer layer of the coating, making the coating more resistant in oxidizing environments, while increasing the relative amount of chromium. It has been found that the increase results in a predominance of chromium oxide, which is more resistant to sulfur-containing environments. By thus adjusting the relative amounts of aluminum and chromium, the usefulness of the coating can also be varied. According to another aspect of the invention, a method of forming a composite coating comprises a method in which the particles combine a chromium-containing material with an oxide of a rare earth metal and/or an oxide of a metal from a group of the Periodic Table of the Elements. characterized by including;
The coating is then aluminized. Preferably the particles also include an aluminum-containing material and preferably the aluminizing process is a pack-aluminizing process.
Consisting of The material used in this method may be aluminum powder or a mixture of aluminum and aluminum oxide. Preferably, the aluminum is in the form of an alloy with chromium. Pack aluminization is carried out at high temperatures.
The aluminum diffuses to the surface of the electrodeposited coating, thereby forming a bond. This coating is then heated to 1000℃
It may be heat treated by holding for about 4 hours, or it may be heat treated during use. The materials described with respect to the first method can also be used in the second method to achieve the same effect. Coating methods include electrolytic or electroless methods and are described in British Patent Nos. 1218179 and 1224166 by the applicant.
No. 1,329,081 and No. 1,347,184 may be used. Reference example UK patent application No. 7906521 by the applicant,
50.8mm (2 inches) x 25.4mm (1 inch) x 3.2mm (1/8 inch) using the device described in Serial No.
A composite coating consisting of a cobalt matrix containing particles of lime-stabilized zirconia and particles of an aluminum-chromium alloy was formed on a thick stainless steel plate. Tank with cobalt sulfate 450g/, boric acid 30g
g/, and a solution containing 2.5 g/ of sodium chloride. This solution in the tank
To 125, 10 ml of Canning's pit prevention liquid was added. The board to be coated is soaked in cyanide cleaner for 2 minutes, then rinsed with water and soaked in 50% sulfuric acid.
Pretreatment consisted of etching by soaking for 30 seconds, then rinsing with water, and giving a nickel strike by plating in a nickel bath for 3 minutes at a current density of 3.9 amperes/dm ² . The plate was fixed in a plating cylinder and connected to the cathode contact. About the volume of a cylinder
40g/lime stabilized zirconia powder and 600g/
chromium-aluminum alloy powder (both 2
(having an average particle size of ˜5 μm) was placed in a cylinder and the opening of the cylinder through which the plate to be coated and the particles were placed was closed. The cylinder was then submerged in the solution in a tank and rotated at 3 revolutions/min while performing complex plating at a voltage of 2.5-3 V and a current density of approximately 2.7 Amps/ ^dm2 . The solution temperature was maintained at 50°C and the solution had a pH of 4.5-5. After plating was allowed to proceed for a sufficient time to provide a plating thickness of 0.05 mm, plating was stopped. The plates were then held at 1000°C for 4 hours, cooled and examined. It was found that the plate had formed a tightly adherent coating with a uniform distribution of particles. The coating had a particle content of approximately 2% by volume zirconia and 30% by volume of chromium-aluminum alloy. EXAMPLE Pack aluminization was carried out as follows on a turbine blade coated and treated according to the reference example. Place the coated vane on a tray, place the alumina,
Surrounded by a mixture of pure aluminum powder and ammonium fluoride powder. The tray was then placed in a retort filled with argon gas. The retort was placed in a furnace and heated at 890°C for 8 hours. after that,
The retort was removed and the coated blades were removed from the powder pack. The blades were then heat treated in vacuum at 1100°C for 1 hour and then at 870°C for an additional 16 hours to improve the aluminum concentration distribution. This is a typical pack aluminization process. Compositional analysis of the aluminized coatings was performed using energy dispersive X-ray analysis. The analysis was performed on a region 64 μm wide and 2-5 μm deep, and the following results were obtained.

[Front] Cover

Claims (1)

[Claims] 1 Electrodeposit a metal matrix from a plating bath,
A method for producing a composite electrodeposited coating comprising simultaneously electrodepositing a portion of the amount to be included in a matrix of particles substantially insoluble in a plating bath, wherein a portion of the particles contain a chromium-containing substance; consisting of an aluminum-containing substance and an oxide of a rare earth metal and/or an oxide of a group metal in the periodic table; the chromium-containing substance is chromium or a chromium alloy;
The aluminum-containing material is aluminum or an aluminum alloy, and the chromium-containing material and the aluminum-containing material are selected from chromium-aluminum powder alloys and chromium-aluminum powder alloys mixed with chromium and/or aluminum. characterized in that the remainder of the particles is provided by pack aluminizing the coating obtained after electrodepositing the metal matrix and some of the particles at high temperatures to diffuse the aluminum onto the surface of the coating. A method of manufacturing a composite electrodeposited coating.