WO2009120629A1 - High temperature resistant coating compositions - Google Patents
High temperature resistant coating compositions Download PDFInfo
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- WO2009120629A1 WO2009120629A1 PCT/US2009/037960 US2009037960W WO2009120629A1 WO 2009120629 A1 WO2009120629 A1 WO 2009120629A1 US 2009037960 W US2009037960 W US 2009037960W WO 2009120629 A1 WO2009120629 A1 WO 2009120629A1
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- WIPO (PCT)
- Prior art keywords
- aluminum
- bonding solution
- solution
- coating composition
- coating
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Classifications
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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
- C23C22/00—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C22/73—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals characterised by the process
- C23C22/74—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals characterised by the process for obtaining burned-in conversion coatings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01L—CHEMICAL OR PHYSICAL LABORATORY APPARATUS FOR GENERAL USE
- B01L99/00—Subject matter not provided for in other groups of this subclass
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/34—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing cold phosphate binders
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01L—CHEMICAL OR PHYSICAL LABORATORY APPARATUS FOR GENERAL USE
- B01L2200/00—Solutions for specific problems relating to chemical or physical laboratory apparatus
- B01L2200/06—Fluid handling related problems
- B01L2200/0647—Handling flowable solids, e.g. microscopic beads, cells, particles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01L—CHEMICAL OR PHYSICAL LABORATORY APPARATUS FOR GENERAL USE
- B01L2200/00—Solutions for specific problems relating to chemical or physical laboratory apparatus
- B01L2200/06—Fluid handling related problems
- B01L2200/0647—Handling flowable solids, e.g. microscopic beads, cells, particles
- B01L2200/0652—Sorting or classification of particles or molecules
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01L—CHEMICAL OR PHYSICAL LABORATORY APPARATUS FOR GENERAL USE
- B01L3/00—Containers or dishes for laboratory use, e.g. laboratory glassware; Droppers
- B01L3/50—Containers for the purpose of retaining a material to be analysed, e.g. test tubes
- B01L3/502—Containers for the purpose of retaining a material to be analysed, e.g. test tubes with fluid transport, e.g. in multi-compartment structures
- B01L3/5027—Containers for the purpose of retaining a material to be analysed, e.g. test tubes with fluid transport, e.g. in multi-compartment structures by integrated microfluidic structures, i.e. dimensions of channels and chambers are such that surface tension forces are important, e.g. lab-on-a-chip
- B01L3/502761—Containers for the purpose of retaining a material to be analysed, e.g. test tubes with fluid transport, e.g. in multi-compartment structures by integrated microfluidic structures, i.e. dimensions of channels and chambers are such that surface tension forces are important, e.g. lab-on-a-chip specially adapted for handling suspended solids or molecules independently from the bulk fluid flow, e.g. for trapping or sorting beads, for physically stretching molecules
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
- C04B2111/00482—Coating or impregnation materials
- C04B2111/00525—Coating or impregnation materials for metallic surfaces
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
- F05B2230/00—Manufacture
- F05B2230/90—Coating; Surface treatment
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
- F05B2260/00—Function
- F05B2260/95—Preventing corrosion
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
- F05C2201/00—Metals
- F05C2201/02—Light metals
- F05C2201/025—Boron
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
- F05C2201/00—Metals
- F05C2201/02—Light metals
- F05C2201/028—Magnesium
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
- F05C2201/00—Metals
- F05C2201/04—Heavy metals
- F05C2201/0469—Other heavy metals
- F05C2201/0487—Manganese
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
- F05C2203/00—Non-metallic inorganic materials
- F05C2203/08—Ceramics; Oxides
- F05C2203/0865—Oxide ceramics
- F05C2203/0891—Zinc oxide
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
- F05C2253/00—Other material characteristics; Treatment of material
- F05C2253/12—Coating
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31678—Of metal
Definitions
- compositions comprising phosphoric acid and aluminum metal are well known for use in protecting metallic surfaces such as ferrous surfaces from corrosion.
- particulate metallic material such as aluminum flake and/or powder
- a phosphoric acid bonding solution to form a coating composition which is then applied to the metallic surface being treated.
- it may be heated to a first temperature, generally upwards of 500° F (260° C), until the coating is rendered essentially water insoluble.
- the coated surface may be cured at a second temperature, generally above 1000 0 F (538 0 C) to form the final protective coating.
- a problem which arises in this coating process is that when the particulate metallic material is combined with the phosphoric acid bonding solution, the acidic bonding solution can react with the metallic material. Such reactions can be very violent, causing the flake and/or powder to burn or even explode, or less violent, simply resulting in the conversion of the metallic material into various salts. In either case, such reactions interfere with the formation of suitable protective coatings.
- Allen U.S. Patent 3,248,251 describes coating compositions consisting essentially of a slurry of solid inorganic particulate material (such as aluminum) in an aqueous acidic bonding solution containing dissolved metal chromate, dichromate or molybdate, and phosphate. It was found that the addition of chromates or molybdates to the acidic bonding solution effectively passivated the solution toward aluminum and inhibited the oxidation of metallic aluminum, allowing particulate aluminum to be combined with the bonding solution without the undesirable chemical reaction between the acidic solution and the aluminum. These so-called Allen coatings have been successfully used to provide high quality coatings which protect ferrous metal alloy surfaces from oxidation and corrosion, particularly at high temperatures.
- the bonding solution component of the coating composition requires sufficient aluminum ions in solution so that it is substantially equilibrated with respect to aluminum metal pigment, i.e., that the amount of aluminum ions in solution be substantially at the saturation point and therefore, essentially inert with respect to any subsequent addition of aluminum metal pigment.
- Stetson discloses using magnesium (either MgO or MgCO 3 ) to at least partially neutralize the aqueous phosphoric acid mixture, either before or after equilibration of the mixture with aluminum.
- Stetson et al. U.S. Patent 5,279,650 discloses a seal coating composition of the coating disclosed in the '649 patent which also contains iron oxide (Fe 2 O 3 ) powder.
- All three coating compositions are designed to avoid the use of the chromium and molybdenum ions and require the bonding solution to be equilibrated with respect to further additions of aluminum.
- the addition of V 2 Os demonstrates the addition of a toxic substance, listed on the OSHA extremely hazardous substance list.
- a bonding solution for use in forming a ferrous alloy coating composition consists essentially of phosphoric acid, a source of magnesium ions, and a leachable corrosion inhibitor.
- the bonding solution has a pH in the range of about 2 to about 4.5, usually from about 2.5 to about 3.5, and often from about 2.7 to about 3.3.
- additional amounts of acid or base may be added to the composition as needed.
- a water-soluble phosphoric acid or acid salt such as magnesium dihydrogen phosphate may be added.
- a coating composition comprises the bonding solution and particulate metallic material such as aluminum.
- the particulate metallic material may be of any suitable form, such as powder, flake, or a combination of powder and flake.
- a method of protecting a substrate comprises applying the coating composition to a metal surface of the substrate, and heating the coated substrate to cure the coating composition.
- the bonding and coating compositions usually are free or substantially free of chromium, especially hexavalent chromium and molybdate and other toxic metals, like nickel and vanadium. Though free or substantially free of such objectionable metals, the compositions are stable for periods of time adequate to apply the coating, especially for periods exceeding 1 hour, usually more than 4 and often more than 8 hours. Some compositions are stable for several days and remain liquid for many weeks.
- the coatings are very satisfactory, in general meeting or exceeding the standards of the Allen coatings in terms of resistance to oxidation and corrosion, especially at high temperature.
- the bonding and coating compositions exhibit such stability and performance characteristics without the need for adding sources of zinc ions and/or aluminum ions as described in U.S. Patent 5,478,413, thus simplifying the compositions and their manufacture.
- the coatings are especially well suited for turbine compressor airfoils, like blades, vanes, stators, and the like.
- the bonding solution may be prepared by first preparing a binder solution by combining water, phosphoric acid, a source of magnesium ions, and optionally a source of borate ions.
- the leachable corrosion inhibitor may then be added to the buffered binder solution to prepare the bonding solution.
- the leachable corrosion inhibitor and/or other components of the bonding solution may have low or reduced solubility or miscibility in water or in the aqueous phosphoric acid. Such less soluble or miscible components may be present in emulsion or other non- solution form.
- aqueous bonding solution and “bonding solution” are thus intended to include compositions in which one or more components may not be fully dissolved, but may be emulsified or dispersed or in another form. This statement applies to components described herein as well as others not described.
- a coating composition may be prepared by combining the bonding solution and a solid particulate metallic material, such as aluminum powder.
- a solid particulate metallic material such as aluminum powder.
- other metal particles may be used, such as those disclosed in the above-referenced Allen patent.
- the coating composition may contain other components conventionally used in the coating industry, such as non-metallic pigments like alumina, zirconia, ceria, and/or other mixed metal oxides.
- the coated ferrous parts exhibit very satisfactory properties, generally equivalent or better than those achieved by the coatings described in the Allen and Stetson patents.
- the aqueous bonding solution contains phosphoric acid, a source of magnesium ions, and a leachable corrosion inhibitor.
- the pH of bonding solution may be adjusted to the range of about 2 to about 4.5, usually from about 2.5 to about 3.5, and often from about 2.7 to about 3.3.
- the bonding solution is stable, that is unreactive or substantially unreactive (or inert) to metallic (e.g., aluminum) particles added subsequently.
- metallic e.g., aluminum
- the coating composition exhibits no or essentially no visible reaction when aluminum particles are admixed to the bonding solution for at least up to one hour, often up to 4 hours, and in some instances up to 8 hours or more.
- the magnesium ions in the bonding solution may be supplied by way of any convenient source such as in the form of magnesium carbonate, magnesium oxide or hydroxide, magnesium metal, or combinations thereof.
- the magnesium dissolves in the phosphoric acid forming the metal ions and water and/or gas.
- the amount added alone or in combination with the other compounds should be sufficient to bring the pH within the desired range or somewhat below or above the range so that upon addition of the other compound(s) the pH will be within the desired range.
- the bonding solution also includes one or more leachable corrosion inhibitors (sometimes also referred to as leachable pigments).
- the leachable corrosion inhibitor is capable of inhibiting or passivating the corrosion of the metal substrate.
- the leachable cation(s) may in some instances serve to passivate or stabilize the aluminum metal powder.
- Pigments are often used in the paint industry to provide color or opacity, or to modify surface hardness, wetting properties, or other characteristics of polymer films. Pigments also may be used to provide corrosion resistance as barriers, e.g., flake-like pigments.
- anticorrosive pigments are selectively leached of specific ions or neutral compounds that alter the rate of corrosion of metallic substrates. For example, strontium chromate and zinc chromate leach small amounts of chromate ion, which effectively passivates most metals in neutral aqueous solutions.
- such pigments are used only in porous primers which are topcoated with an effective barrier polymer film that seals and protects the primer from leaching except in those situations when the film is damaged or permeated.
- inorganic aluminum pigmented slurry coatings based on acidic phosphate binders have no organic carbon based polymer as the film former in the coating.
- the slurry coatings instead are water-based and are very porous yet they are often used without a topcoat or sealer.
- neutral modified phosphate pigments as corrosion inhibitors creates several unexpected improvements, such as ( 1 ) the pot life (mixed usable coating life) of the coating is extended significantly; (2) the chemical attack of the acid phosphate binder solution on steel substrates is reduced or eliminated; and (3) the performance of the applied aluminum coating under extreme conditions (salt spray, high temperature cycling, etc.) is enhanced.
- the concentration of the leachable corrosion inhibitor in the bonding solution may vary over a wide range depending on such factors as the identity of the leachable corrosion inhibitor, the identity and amount of other components present, and the targeted properties of the coating composition. For example, higher concentrations may be present in compositions that do not contain metal (e.g., aluminum) powder and/or where the leachable corrosion inhibitor is the only pigment present.
- the amount of leachable corrosion inhibitor may range from about 2 to about 80 g, often from about 2 to about 50 g, per 100 ml of binder solution. In bonding solutions that are combined with aluminum powder, the amount of leachable corrosion inhibitor often ranges from about 2 to about 15 g per 100 ml of binder solution.
- compositions may contain other compatible known ingredients such as surfactants, wetting agents and other conventional additives.
- compositions exhibiting satisfactory stability and performance characteristics can be prepared without the need for adding sources of zinc ions and/or aluminum ions as described in U.S. Patent 5,478,413.
- Relatively small quantities of ions such as zinc and aluminum may be present in the aqueous compositions as a result of equilibrium reactions involving metals contained in the leachable corrosion inhibitor.
- the bonding solution may also contain quantities of other ions, such as calcium and/or strontium ions. In some instances the bonding solution is free or substantially free of Fe ions and/or Mn ions.
- the composition may also contain borate ions, which may be supplied by any convenient form such as boron oxide, boric acid, and soluble borate salts.
- borate ions may be supplied by any convenient form such as boron oxide, boric acid, and soluble borate salts.
- Non- limiting examples of borate compounds are listed in the Handbook. Boron oxide hydrates into boric acid and then reacts forming magnesium borate in solution.
- the bonding solution may be prepared by first preparing a binder solution by combining water, phosphoric acid, a source of magnesium ions, and optionally a source of borate ions.
- the binder solution is buffered, e.g., to a pH of about 2 to about 3, often from about 2.4 to about 2.7.
- the leachable corrosion inhibitor may then be added to the buffered binder solution to prepare the bonding solution.
- the coating slurry composition may be formed by mixing the above described bonding solution with the metal particles, e.g., aluminum particles in the form of powder, flake, or a combination thereof.
- the bonding solution is essentially inert with respect to any further reaction with the added aluminum. No visible reaction between the added aluminum particles and the phosphoric acid is apparent in the coating composition for at least one hour and in some instances for as long as eight hours or more.
- the bonding solutions are particularly useful for forming coating compositions for ferrous metal alloy substrates when combined with particulate aluminum.
- Particulate aluminums suitable for use in such coating compositions are well known, and have been discussed at length in the patent literature.
- such particulate aluminums are set forth in Mosser U.S. Patents 4,537,632, 4,544,408, 4,548,646, 4,617,056, 4,659,613, and 4,863,516, which is particularly directed to the use of non-leafing aluminum flake in combination with atomized aluminum particles; and Mosser U.S. Patents 4,889,558 and 5,1 16,672, all of which are incorporated herein by reference.
- a majority of chromate/phosphate based compositions that utilize aluminum particles use atomized and/or flaked particles of various sizes for coatings with different properties. These are of course also suitable for the present bonding and coating compositions.
- aluminum When aluminum is used in the compositions it may be gas atomized spherical of an average size of 2.5-10 ⁇ m, air atomized of an average size of 4.5-10 ⁇ m, flake aluminum; flake/atomized mixtures; and aluminum alloys. Larger particles as well as smaller particles can be used.
- the slurry coating compositions may be applied in a conventional way to the ferrous metal alloy surface to be coated. Manners of application are described in the patents referred to above and incorporated herein by reference. Generally, it is desirable to degrease the part to be coated, blast with aluminum oxide abrasive, and apply the coating by any suitable means, such as by spraying, brushing, dipping, dip spinning, etc., drying until the color of the coating turns grayish, curing the coating at a temperature of about 650 0 F (343 0 C) for 15 minutes or longer, curing at higher or lower temperatures if desired.
- the slurry is preferably applied in two coats or layers, each about 0.001 inch (25 ⁇ m) in thickness, then, if desired, dried at about 180 0 F (82 0 C) for 15 to 30 minutes and then cured at 650 0F (343 0 C) for 30 to 60 minutes after each coat.
- the coatings as cured at 650 0 F (343 0 C) are not electrically conductive and therefore can not provide galvanic protection against corrosion of the underlying substrate material.
- the coating may be made electrically conductive by burnishing with glass beads, abrasive media at low pressure or mechanically cold worked in other ways to produce a conductive sacrificial coating or by heating as specified in MIL-C-81751B specification (incorporated herein by reference). In this manner the coatings can, by mechanical or thermal processes, be made electrically conductive and thereby produce galvanic as well as barrier protection of the underlying ferrous alloy substrate.
- the surface of the coating may be sealed with a bonding solution (seal coat) to further increase the oxidation and corrosion protection provided by the coating, and to decrease the rate of consumption of aluminum in the coating during service.
- This bonding solution can but need not be a bonding solution as described herein.
- the seal coat may, in addition to having no additional fillers or pigments, contain pigments and fillers typical used in the industry. These include such materials as metal oxides such as alumina, silica, chromia, and titania, as well as mixed metal oxides and oxide spinels such as copper, iron and manganese chromite, and magnesium ferrite.
- the purpose of the pigments may be to increase oxidation and corrosion protection as well as provide improved application properties.
- the seal coats may be dried and cured at the same time and temperature as the above described slurry coatings.
- topcoats include compositions containing phosphate and nitrate ions as described in Myers et al. U.S. Patent 5,968,240 and compositions containing phosphate and chromium III (Cr 3+ ) ions as described in Myers et al. 6,224,657, the disclosures of which are incorporated herein by reference.
- a binder for a bonding solution was prepared by combining deionized water, phosphoric acid, boron oxide, and magnesium carbonate in the amounts listed in the table below.
- a bonding solution was prepared by mixing 100 ml of the binder with 4.2 g of Heucophos ZPA. The resulting pH of this bonding solution was 3.1.
- a coating composition was prepared by mixing 100 ml of the bonding solution with 70 g aluminum powder (5 ⁇ m).
- Coating compositions were prepared in a manner described in Example 1 from bonding solutions which had the following compositions.
- Coating composition were prepared in a manner described in Example 1 from bonding solutions which had the following compositions.
- Oxidation corrosion resistance 3 x 4 inch panels with one coat, 0.8-1.0 mil thick (20-25 ⁇ m) were evaluated according to an industry standard oxidation corrosion test. Panels were bead burnished, heat treated at 700 0 F (371 0 C) for 23 hours, then at 1075 0 F (579 0 C) for 4 hours, scribed, and placed in a 5% salt spray per ASTM B l 17 for 400 hours.
- Heat cycle salt spray 4 x 4 inch panels with 2 coats, 2 cures, 1.5 mil (38 ⁇ m) thick, for 10 heat / salt spray cycles were evaluated where one cycle consisted of 7.5 hours at 850 0 F (454 0 C) and 15.5 hours in 5% salt spray. Coated panels were grit burnished and scribed prior to testing.
- Panels of 1010 mild steel were prepared by cutting 0.030 inch (0.75 mm) thick sheet stock and stamping each panel with a unique ID code. The panels were thermally degreased at 650 0 F (343 0 C) then grit blasted with 100 mesh alumina grit at 60 psi. An oxidation step consisting of 650 0 F (343 0 C) for one hour was performed prior to coating application.
- Table I provides the results of the pot life / stability observations for each coating. Comparative Example 3 had a very short pot life and showed signs of reaction with the substrate. This demonstrates the adverse effects in stability when a leachable corrosion inhibitor is not present.
Abstract
Description
Claims
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
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CA2719590A CA2719590C (en) | 2008-03-28 | 2009-03-23 | High temperature resistant coating compositions |
CN2009801111526A CN101981229A (en) | 2008-03-28 | 2009-03-23 | High temperature resistant coating compositions |
EP20090725236 EP2255027A1 (en) | 2008-03-28 | 2009-03-23 | High temperature resistant coating compositions |
BRPI0910095A BRPI0910095A2 (en) | 2008-03-28 | 2009-03-23 | aqueous binding solution, aqueous phosphoric acid coating composition, method of coating a part having a ferrous alloy surface, and a coated part. |
JP2011501950A JP5654445B2 (en) | 2008-03-28 | 2009-03-23 | High temperature resistant coating composition |
Applications Claiming Priority (2)
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US12/057,620 US7789953B2 (en) | 2008-03-28 | 2008-03-28 | High temperature resistant coating compositions |
US12/057,620 | 2008-03-28 |
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WO2009120629A1 true WO2009120629A1 (en) | 2009-10-01 |
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PCT/US2009/037960 WO2009120629A1 (en) | 2008-03-28 | 2009-03-23 | High temperature resistant coating compositions |
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US (2) | US7789953B2 (en) |
EP (1) | EP2255027A1 (en) |
JP (1) | JP5654445B2 (en) |
CN (2) | CN104805430A (en) |
BR (1) | BRPI0910095A2 (en) |
CA (1) | CA2719590C (en) |
WO (1) | WO2009120629A1 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2014140018A1 (en) * | 2013-03-13 | 2014-09-18 | Commissariat à l'énergie atomique et aux énergies alternatives | Binder and the use thereof for conditioning waste containing aluminium metal |
US9644102B2 (en) | 2014-05-23 | 2017-05-09 | A Et A Mader | Method of manufacturing a corrosion-resistant sacrificial protective coating |
Families Citing this family (28)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US7789953B2 (en) * | 2008-03-28 | 2010-09-07 | Praxair S.T. Technology, Inc. | High temperature resistant coating compositions |
WO2009152330A1 (en) | 2008-06-12 | 2009-12-17 | Latitude 18, Inc | Inorganic phosphate resins and method for their manufacture |
CN102781871B (en) | 2009-12-11 | 2014-11-26 | 18纬度有限公司 | Inorganic phosphate compositions and methods |
US8557342B2 (en) * | 2009-12-11 | 2013-10-15 | Latitude 18, Inc. | Inorganic phosphate corrosion resistant coatings |
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Also Published As
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JP5654445B2 (en) | 2015-01-14 |
US20090246389A1 (en) | 2009-10-01 |
CA2719590C (en) | 2014-02-11 |
US7789953B2 (en) | 2010-09-07 |
US20100288158A1 (en) | 2010-11-18 |
BRPI0910095A2 (en) | 2015-12-15 |
JP2011515589A (en) | 2011-05-19 |
EP2255027A1 (en) | 2010-12-01 |
CN104805430A (en) | 2015-07-29 |
CA2719590A1 (en) | 2009-10-01 |
US7993438B2 (en) | 2011-08-09 |
CN101981229A (en) | 2011-02-23 |
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