Method for forming coatings by electrolyte discharge and coating

Electrolysis: processes – compositions used therein – and methods – Electrolytic coating – Involving measuring – analyzing – or testing

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205106, 205108, 205109, 205121, 205133, 205137, 205146, 205316, 205319, 205324, C25D 2112, C25D 518, C25D 500, C25D 1104

Patent

active

057208662

ABSTRACT:
A method for forming relatively thick composite coatings on a region of the surface of a metallic member includes exposing the surface region to an electrolyte fluid, either by immersion or by spraying the electrolyte against the surface region. A preferred electrolyte fluid is an aqueous solution including an electrolytic agent, a passivating agent and a modifying agent in the form of a solute or a powder suspended in the solution. A voltage signal is applied to induce a current flow of constant magnitude between the metallic member and the electrolyte fluid so that the metallic member interacts with the passivating agent to form a passive oxide layer on the surface region. The voltage signal increases in magnitude until local voltage reaches a breakthrough level across separate highly localized discharge channels along the surface region of the metallic member. At this breakthrough level, localized plasmas including components of the oxide layer and the modifying agent form near the discharge channel and reacts to form the coating. At some point after the discharges appear, the signal is changed to a series of unipolar anodic pulses interspersed with cathodic pulses which serve to stabilize the growth of the coating.

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