Specialized metallurgical processes – compositions for use therei – Compositions – Loose particulate mixture containing metal particles
Reexamination Certificate
1999-11-18
2001-01-09
Mai, Ngoclan (Department: 1742)
Specialized metallurgical processes, compositions for use therei
Compositions
Loose particulate mixture containing metal particles
C427S376400, C428S640000
Reexamination Certificate
active
06171359
ABSTRACT:
FIELD OF INVENTION
The present invention relates to the surface treatment technology of metal articles with the purpose of receiving on their surface protecting and decorative coatings.
In particular, this invention relates to the thermal diffusion coating technology for receiving protecting and decorative coatings on metal surface by virtue of thermal activation of atoms surrounding that surface and their induced diffusion thereinto.
In the industry the process of such kind is known for Zinc saturation of metallic surfaces consisting of iron or iron alloys This process is known in the art as “sherardizing” (named after its English inventor Sherard O. Cowper-Coles).
The process is carried out by heating up to 380-450 degrees of Celsius of iron made articles embedded within zinc-containing powder mixture.
The resulting diffusion coating consists of inter-metallic compounds and such coatings are defined by improved corrosion stability compared to coatings received by alternative technologies, e.g. electroplating or hot-dipping.
BACKGROUND OF INVENTION
A general description of the sherardizing process can be found in monographs or handbooks, for example, “Corrosion and Protection of Metals” by Bakhvalov and Turkovskaya, Pergamon Press, 1965, or “Zincification”, handbook edited by Proskurkin, Moscow, Metallurgy, 1988.
The typical sherardizing process is described in these and others handbooks, as including the following general steps:
preparing of articles surface by chemical or shot blasting treatment;
placing of cleaned articles into a drum, filled with zinc powder and inert filler zinc oxide, sand, aluminum oxide and others). The amount of inert filler and zinc powder can be varied from 1:10 to 1:1;
sealing of the drum and heating up to the temperature within the range 380-450 degrees of Celsius and isothermal heating for 1-4 hours;
In order to accelerate the process the drum can be rotated with a small velocity;
After completing the heating step the coated articles are discharged from the drum and transferred to finishing operation, usually passivation.
The coating received by this process consists of several phases, defined by different zinc-iron ratio depending on heating temperature and time and composition of zinc-containing mixture. The coating may have thickness from 5 to 200 and more microns. The coating color is usually gray, and after passivation it becomes dark-gray.
The problem with which usually is associated with sherardizing is melting and coalescence of zinc powder particles due to the fact that Zn melting point is close to the process temperature. Usually this problem is solved by introducing into mixture of an inert additive, providing for physical barrier between the Zinc particles or creating this barrier artificially on the surface of Zn particles.
In SU 1534091 there is disclosed steam-oxidation treatment of Zn powder resulting in creating on Zn particles oxides and hydroxides preventing melting of adjacent particles together. In SU 560001 there is disclosed sherardizing, which is carried out in within the powder mixture, consisting of (wt. %): Cr 10-20, Zn 10-20, silicon oxide 10-15, chromic oxide 10-20, NH
4
Cl 1-3, remainder Al
2
O
3
.
In CN 1084582 there is described sherardizing mixture consisting of Zinc, guarzite and small additions of Pb.
The above mentioned approach based on introduction of inert additives into sherardizing mixture overcomes the above mentioned problem and is widely used in industry.
It should be pointed out however that sherardizing within powder mixtures with inert additivies does not improve corrosion resistance in comparison with coatings deposited by alternative technologies and does not allow to control the coating color.
For example corrosion resistance of coatings obtained by sherardizing are worse in conditions of Salt-Spray (the standard environment for determination corrosion stability of coatings) that zinc coatings deposited electrolytically. Despite some improvement of corrosion resistance can be achieved after passivation, it does not always satisfy customers requirements and besides the passivation is associated with deterioration of coating visual appearance because its color becomes dark-gray.
In FR 2451405 there is described that in order to impart brilliance to an article after sherardizing process it is treated by phosphatization and then is polished It should be realized however that in order to provide such a coating with reasonable corrosion resistance it should be passivated. Seeing that passivation results in a colorless pasivating film it can be readily understood that after passivation the brilliant appearance will be lost. It should be also mentioned that phosphatizing with subsequent polishing doesn't provide for an opportunity to control the coating color.
OBJECTS & SUMMARY OF THE INVENTION
The main object of the present invention is to provide for a new zinc-containing powder mixture for sherardizing process and a method for its preparation in which the above mentioned drawbacks are sufficiently reduced or overcome.
In particular, the first object of the present invention is to provide for a new and improved zinc-containing powder mixture for use in sherardizing process which enables receiving of colored coatings with wide range of color and with improved corrosion resistance.
The second object of the present invention is to provide for a simple and cheap method of preparation of such a mixture.
The above and other objects and advantages of the present invention can be achieved in accordance with the following combination of its essential features referring to different embodiments thereof.
A powder mixture comprising a base metal powder suitable for use in thermal diffusion coating process in which an article to be coated is embedded into said powder mixture and is thermally treated therein so as to cause diffusion of atoms of said base metal within said article,
characterized in that said powder mixture comprises 0.1-5 wt. % of an additive consisting of at least one oxide of a metal chosen from the group comprising iron, titanium, chromium, cobalt, nickel, molybdenum, said additive having a particle size not more than 5 micron, and preferably less than 1 micron.
It has been found that by virtue of the above additive it is possible to receive colored coatings with increased corrosion resistance in conditions of Salt Spray Chamber by 50-100%. It should be pointed out that improvement of corrosion resistance and coloration effect does not take place on account of the coating thickness.
The present invention in its various embodiments has only been briefly summarized.
For a better understanding of the present invention as well as its advantages, reference will now be made to the following description of its embodiments.
REFERENCES:
patent: 3436511 (1969-04-01), Rath
patent: 3864093 (1975-02-01), Wolfla
patent: 4124737 (1978-11-01), Wolfla
patent: 4313760 (1982-02-01), Dardi et al.
patent: 4822689 (1989-04-01), Fukubayashi et al.
patent: 4917966 (1990-04-01), Wilde et al.
Avraham Sheinkman
Isaak Shtikan
Levinski Leonid
Victor Samoilov
Blank Rome Comisky & McCauley LLP
Mai Ngoclan
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