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WO2001046324B1 - Erosion-resistant coatings for organic matrix composites - Google Patents

Erosion-resistant coatings for organic matrix composites

Info

Publication number
WO2001046324B1
WO2001046324B1 PCT/US2000/041502 US0041502W WO0146324B1 WO 2001046324 B1 WO2001046324 B1 WO 2001046324B1 US 0041502 W US0041502 W US 0041502W WO 0146324 B1 WO0146324 B1 WO 0146324B1
Authority
WO
WIPO (PCT)
Prior art keywords
erosion
coating
resistant coating
organic resin
mixtures
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2000/041502
Other languages
French (fr)
Other versions
WO2001046324A3 (en
WO2001046324A2 (en
Inventor
Subhash K Naik
Raymond J Sinatra
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Rolls Royce North American Technologies Inc
Original Assignee
Allison Advanced Development Co Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Allison Advanced Development Co Inc filed Critical Allison Advanced Development Co Inc
Priority to EP00992985A priority Critical patent/EP1244544A4/en
Priority to AU49012/01A priority patent/AU4901201A/en
Publication of WO2001046324A2 publication Critical patent/WO2001046324A2/en
Publication of WO2001046324A3 publication Critical patent/WO2001046324A3/en
Publication of WO2001046324B1 publication Critical patent/WO2001046324B1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • 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
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
    • C08J7/04—Coating
    • C08J7/042—Coating with two or more layers, where at least one layer of a composition contains a polymer binder
    • C08J7/0423—Coating with two or more layers, where at least one layer of a composition contains a polymer binder with at least one layer of inorganic material and at least one layer of a composition containing a polymer binder
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
    • C08J7/04—Coating
    • C08J7/043—Improving the adhesiveness of the coatings per se, e.g. forming primers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
    • C08J7/04—Coating
    • C08J7/046—Forming abrasion-resistant coatings; Forming surface-hardening coatings
    • 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

Landscapes

  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Polymers & Plastics (AREA)
  • Medicinal Chemistry (AREA)
  • Health & Medical Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Materials Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Inorganic Chemistry (AREA)
  • Laminated Bodies (AREA)

Abstract

This invention is directed to a coated article having an erosion-resistant coating and a method of providing the erosion-resistant coating to the article. The coated article has an increased useful lifespan and will resist erosion even in high-temperature environments. The coated article includes an organic resin substrate, a high-temperature erosion-resistant coating, and a bonding layer to secure the coating to the substrate. The bond coating can comprise a material selected from zinc, aluminum, aluminum-silicon alloy, chromium, titanium, nickel, silicon, tin, antimony, copper, iron, stainless steel, silver, and mixtures thereof. The erosion-resistant coating can be provided as a substantially non-porous layer comprising a material selected from the group of carbides, fluorides, nitrides, oxides and mixtures thereof of materials such as nickel, cobalt, iron, chromium, tungsten, and molybdenum. The organic resin substrate is prepared to receive the erosion-resistant coating by grip-blasting the resin surface. The metallic bond coat is then applied to the resin surface, and an erosion-resistant coating is deposited on the metallic bond coating.

Claims

AMENDED CLAIMS[received by the International Bureau on 14 August 2001 (14.08.01); original claims 1-43 replaced by amended claims 1-43 (7 pages)]
1. A coated article comprising an organic resin substrate, a metallic bond coating and an erosion-resistant coating, wherein said erosion-resistant coating is provided to have a porosity of less than about 5 % and comprises a material selected from the group consisting of nickel, cobalt, iron, chromium, tungsten, molybdenum, diamond, diamond-like carbon, polyester nylon, carbides, borides, nitrides, oxides, intermetallics, and mixtures thereof.
2. A coated article comprising an organic resin substrate, a metallic bond coating and an erosion-resistant coating, wherein said erosion-resistant coating is provided as a substantially non-porous layer comprising a material selected from the group consisting carbides, borides, nitrides, oxides and intermetallics of tungsten, aluminum, chromium, nickel, silicon, titanium, zirconium, boron, and mixtures of these materials.
3. The coated substrate of claim 1 or 2 wherein the organic resin includes reinforcing material selected from the group consisting of carbon, glass, quartz, kevlar, metal, metal oxides, ceramics and mixtures thereof.
4. The coated substrate of claim 1 or 2 wherein the organic resin comprises a material selected from the group consisting of polyimides, poly(phenyl sulfide)s, polybenzoxazoles, polycarbonates, polyepoxides, polyphthalamides, and polyketones, and mixtures thereof.
5. The coated substrate of claim 1 or 2 wherein the bond coating has a coating thickness of about 0.2 to about 3 mils.
6. The coated substrate of claim 1 or 2 wherein the bond coating comprises a metal selected from the group consisting of zinc, aluminum, aluminum-silicon alloy, chromium, titanium, nickel, silicon, tin, antimony, copper, iron, stainless steel, silver, and mixtures thereof.
7. The coated substrate of claim 1 wherein the erosion-resistant coating is provided as a substantially non-porous layer comprising a material selected from the group consisting of Cr, Mo, W, Co, Ni, NiCr, WC-Co, Ni-B, Ni- SiC, MoAINi, TiN-Mo, Cr3C2-NiCr, SiC, B4C, CrN, CBN, TiN, TiAIN, ZrN, Cr02, Si0 , diamond films, diamond-like carbon and mixtures thereof.
8. The coated substrate of claim 1 or 2 wherein the erosion-resistant coating has a coating thickness of about 0.1 to about 4 mils.
9. The coated substrate of claim 2 wherein the erosion-resistant coating has a porosity of about about 5 % to about 0.1 %.
10. The coated substrate of claim 1 or 2 wherein the erosion-resistant coating has a porosity of about 2% to about 0.1 %.
1 1. A method of providing an erosion-resistant coating to a surface of an organic resin, said method comprising: preparing the surface of the organic resin using an abrasive material; applying a metallic bond coating to the organic resin; and depositing a substantially non-columnar coating comprising a material selected from the group consisting of carbides, borides, nitrides, oxides and mixtures thereof to provide the erosion-resistant coating.
12. A method of providing an erosion-resistant coating to a surface of an organic resin, said method comprising: preparing the surface of the organic resin; applying a metallic bond coating to the organic resin; and depositing a substantially non-columnar coating having a porosity of less than about 5% and comprising a material selected from the group consisting of carbides, borides, nitrides, oxides and mixtures thereof to provide the erosion- resistant coating.
13. The method of claim 1 1 or 12 wherein the organic resin comprises a polymer is selected from the group consisting of polyimide, poly(phenyl sulfide) polybenzoxazole, polycarbonate, polyepoxide, polyphthalamide, polyketone, and mixtures thereof.
14. The method of claim 11 or 12 wherein the organic resin comprises a reinforcing material.
15. The method of claim 12 wherein preparing the surface of the organic resin includes blasting the surface with an abrasive material.
16. The method of claim 1 1 or 15 wherein the abrasive material used to prepare the surface includes A1 0 or SiC particles having an average particle size of about 45 to about 65 mesh.
17. The method of claim 1 1 or 15 wherein the abrasive material used to prepare the surface includes A1?03 or SiC particles having an average particle size of about 50 to about 60 mesh.
18. The method of claim 1 1 or 12 wherein preparing the surface of the organic resin includes abrasive cleaning the organic resin surface with an abrasive material at a pressure of about 15 to about 25 psig.
19. The method of claim 11 or 12 wherein the metallic bond coating includes a metal selected from the group consisting of zinc, aluminum, aluminum- silicon alloy, chromium, titanium, nickel, silicon, tin, antimony, copper, iron, stainless steel, silver, and mixtures thereof.
20. The method of claim 11 or 12 wherein applying a metallic bond coating consists of applying a single bond coating.
21. The method of claim 11 or 12 wherein the metallic bond coating has an average thickness of about 0.2 mils to about 3 mils.
22. The method of claim 11 or 12 wherein the metallic bond coating is applied using a thermal spray technique or wire spray process or plating or CVD process.
23. The method of claim 11 or 12 wherein applying the metallic bond coating includes maintaining the organic resin at a temperature below about 500 °F.
24. The method of claim 11 or 12 wherein the erosion-resistant coating has an average thickness of about 0.1 mil to about 4 mils.
25. The method of claim 11 or 12 wherein the erosion-resistant coating comprises a material selected from the group consisting essentially of Cr, Mo, W,
Co, Ni, NiCr, WC-Co, Cr3C2-NiCr, SiC, B4C, CrN, SBN, TiN, TiAlN, ZrN, Cr02, Si02, diamond films and mixtures thereof.
26. The method of claim 1 1 wherein the erosion-resistant coating has a porosity of less than about 5%.
27. The method of claim 12 or 26 wherein the erosion-resistant coating has a porosity of less than about 2%.
28. The method of claim 11 or 12 wherein deposition of the substantially non-columnar coating includes maintaining the organic resin at a temperature below about 500 °F.
29. The method of claim 11 or 12 wherein the erosion-resistant coating is deposited using a CVD, thermal spray, electroplating, electroless plating overlay or cathodic arc deposition technique.
30. A method of adhering an erosion-resistant coating to a surface of an organic resin, the method comprising: abrasively blasting the surface of the organic resin with an abrasive material; applying a bond coating to the surface of the organic resin using a thermal spray technique; and depositing an erosion-resistant coating on the bond coating.
31. The method of claim 30 wherein the organic resin comprises a polymer selected from the group consisting of polyimides, poly(arylene sulfιde)s, polybenzoxazoles, polycarbonates, polyepoxides, polyphthalamides, and polyketones, and mixtures thereof.
32. The method of claim 30 wherein the organic resin comprises a reinforcing material selected from the group consisting essentially of carbon, glass, quartz, kevlar, metal, metal oxides, and ceramics, and mixtures thereof.
33. The method of claim 30 wherein the abrasive material to includes a material selected from the group consisting of A1203 and SiC, and mixtures thereof.
34. The method of claim 33 wherein the abrasive material has a median particle size of about 45 to about 65 mesh.
35. The method of claim 34 wherein the abrasive material has a median particle size of about 50 to about 60 mesh.
36. The method of claim 30 wherein the bond coating includes at least one metal selected from the group consisting of zinc, aluminum, aluminum-silicon alloy, chromium, titanium, nickel, silicon, tin, antimony, copper, iron, stainless steel, silver, and mixtures thereof.
37. The method of claim 30 wherein deposition of the erosion-resistant coating is includes maintaining the organic resin at a temperature below about 500°F.
38. The method of claim 30 wherein the bond coating consists of a single layer.
39. The method of claim 30 wherein the bond coating has an average thickness of about 0.2 mils to about 3 mils.
40. The method of claim 30 wherein the erosion-resistant coating has an average thickness of about 0.1 mil to about 4 mils.
41. The method of claim 30 wherein the erosion-resistant coating comprises a material selected from the group consisting essentially Cr, Mo, W, Co, Ni, NiCr, WC-Co, Cr3C2-NiCr, SiC, B4C, CrN, CBN, TiN, TiAlN, ZrN, Cr02, SiO?, diamond films, and diamond-like carbon, and mixtures thereof.
42. The method of claim 30 wherein the erosion-resistant coating is deposited at a process temperature below about 500 °F.
43. The method of claim 30 wherein the erosion-resistant coating is deposited using a CVD, thermal spray, electroplating, electroless plating overlay or HVOF technique.
PCT/US2000/041502 1999-10-25 2000-10-24 Erosion-resistant coatings for organic matrix composites Ceased WO2001046324A2 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP00992985A EP1244544A4 (en) 1999-10-25 2000-10-24 Erosion-resistant coatings for organic matrix composites
AU49012/01A AU4901201A (en) 1999-10-25 2000-10-24 Erosion-resistant coatings for organic matric composites

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US42627999A 1999-10-25 1999-10-25
US09/426,279 1999-10-25

Publications (3)

Publication Number Publication Date
WO2001046324A2 WO2001046324A2 (en) 2001-06-28
WO2001046324A3 WO2001046324A3 (en) 2001-11-15
WO2001046324B1 true WO2001046324B1 (en) 2002-01-03

Family

ID=23690124

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2000/041502 Ceased WO2001046324A2 (en) 1999-10-25 2000-10-24 Erosion-resistant coatings for organic matrix composites

Country Status (3)

Country Link
EP (1) EP1244544A4 (en)
AU (1) AU4901201A (en)
WO (1) WO2001046324A2 (en)

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Also Published As

Publication number Publication date
WO2001046324A3 (en) 2001-11-15
EP1244544A2 (en) 2002-10-02
WO2001046324A2 (en) 2001-06-28
EP1244544A4 (en) 2003-01-29
AU4901201A (en) 2001-07-03

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