Metal-coated articles comprising a transition metal region and a platinum-group metal region and related methods

Patent metadata

Field	Value
Publication number	US-12359333-B2
Application number	US-202318459966-A
Country	US
Kind code	B2
Filing date	Sep 1, 2023
Priority date	Sep 2, 2022
Publication date	Jul 15, 2025
Grant date	Jul 15, 2025

Abstract

A metal-coated article that comprises a substrate, a transition metal region adjacent to the substrate, and a platinum-group metal region adjacent to the transition metal region. The transition metal region comprises a transition metal carbide layer adjacent to the substrate. The platinum-group metal region comprises a transition metal/platinum-group metal layer that is adjacent to the transition metal region and a platinum-group metal layer adjacent to the transition metal/platinum-group metal layer. Related methods are also disclosed.

First claim

What is claimed is:

1. A method of forming a metal-coated article, comprising:
electrodepositing a transition metal layer onto a substrate; and converting at least a portion of the transition metal layer to a transition metal carbide layer to form a transition metal region; and
electrodepositing a platinum-group metal layer on the transition metal region; and converting at least a portion of the platinum-group metal layer to a transition metal/platinum-group metal layer on the platinum-group metal layer to form a platinum-group metal region.

2. The method of claim 1 , wherein electrodepositing a transition metal layer onto a substrate comprises electrodepositing the transition metal layer at a temperature in a range of from about 350° C. to about 500° C.

3. The method of claim 2 , wherein electrodepositing a transition metal layer onto a substrate comprises electrodepositing the transition metal layer from an electrolyte comprising LiBr, KBr, and CsBr.

4. The method of claim 1 , wherein electrodepositing a platinum-group metal layer onto the transition metal region comprises electrodepositing the platinum-group metal layer from an alkali halide salt electrolyte at a temperature in a range of from about 350° C. to about 500° C.

5. The method of claim 4 , wherein electrodepositing the platinum-group metal layer from an alkali halide salt electrolyte comprises electrodepositing the platinum-group metal layer from an electrolyte comprising LiBr, KBr, and CsBr.

6. The method of claim 1 , wherein converting at least a portion of the transition metal layer to a transition metal carbide layer comprises annealing the substrate and the transition metal layer at a temperature from about 500° C. to about 600° C.

7. The method of claim 1 , wherein converting at least a portion of the platinum-group metal layer to a transition metal/platinum-group metal layer comprises annealing the transition metal region and the platinum-group metal layer at a temperature from about 500° C. to about 600° C.

8. A method of forming a metal-coated article, comprising:
forming an as deposited transition metal layer on a substrate;
annealing the as deposited transition metal layer to convert at least a portion of the as deposited transition metal layer to a transition metal carbide layer;
forming an as deposited platinum-group metal layer on the transition metal carbide layer; and
annealing the as deposited platinum-group metal layer to convert at least a portion of the as deposited platinum-group metal layer to a transition metal/platinum-group metal layer.

9. The method of claim 8 , wherein annealing the as deposited transition metal layer to convert at least a portion of the as deposited transition metal layer comprises converting substantially all of the as deposited transition metal layer to the transition metal carbide layer.

10. The method of claim 8 , wherein annealing the as deposited platinum-group metal layer to convert at least a portion of the as deposited platinum-group metal layer to a transition metal/platinum-group metal layer comprises forming the platinum-group metal layer and a platinum-group metal layer.

11. A method of forming a metal-coated article, comprising:
electrodepositing one or more transition metal layers onto a substrate layer from an electrolyte comprising an alkali metal halide; and converting at least a portion of the one or more transition metal layers to a transition metal carbide layer to form a transition metal region; and
electrodepositing one or more platinum-group metal layers on the transition metal region; and converting at least a portion of the one or more platinum-group metal layers to a transition metal/platinum-group metal layer on the platinum-group metal layer to form a platinum-group metal region.

12. The method of claim 11 , wherein converting at least a portion of the one or more transition metal layers to a transition metal carbide layer to form a transition metal region comprises converting at least a portion of the one or more transition metal layers to a transition metal carbide layer exhibiting a substantially homogenous chemical composition.

13. The method of claim 11 , wherein converting at least a portion of the one or more transition metal layers to a transition metal carbide layer to form a transition metal region comprises converting at least a portion of the one or more transition metal layers to a transition metal carbide layer exhibiting a gradient of carbon in the transition metal carbide layer.

14. The method of claim 11 , wherein converting at least a portion of the one or more transition metal layers to a transition metal carbide layer to form a transition metal region comprises converting at least a portion of the one or more transition metal layers to a transition metal carbide layer to form a transition metal region comprising a transition metal layer and a transition metal carbide layer, wherein a relative thickness of the transition metal carbide layer is greater than a relative thickness of the transition metal layer.

15. The method of claim 11 , wherein converting at least a portion of the one or more transition metal layers to a transition metal carbide layer to form a transition metal region comprises converting at least a portion of the one or more transition metal layers to a transition metal carbide layer to form a transition metal region comprising a transition metal layer and a transition metal carbide layer, wherein a ratio of a thickness of the transition metal carbide layer to a thickness of the transition metal layer is about 3:1.

16. The method of claim 11 , wherein electrodepositing one or more platinum-group metal layers on the transition metal region comprises electrodepositing one or more of platinum, palladium, rhodium, iridium, ruthenium, and osmium.

17. The method of claim 11 , wherein electrodepositing one or more platinum-group metal layers on the transition metal region comprises electrodepositing one or more of ruthenium and osmium.

18. The method of claim 11 , wherein converting at least a portion of the one or more platinum-group metal layers to a transition metal/platinum-group metal layer on the platinum-group metal layer to form a platinum-group metal region comprises converting at least a portion of the one or more platinum-group metal layers to a transition metal/platinum-group metal layer exhibiting a homogeneous chemical composition of the transition metal and the platinum-group metal.

19. The method of claim 11 , wherein converting at least a portion of the one or more platinum-group metal layers to a transition metal/platinum-group metal layer on the platinum-group metal layer to form a platinum-group metal region comprises converting at least a portion of the one or more platinum-group metal layers to a transition metal/platinum-group metal layer exhibiting a heterogeneous chemical composition of the transition metal and the platinum-group metal.

20. The method of claim 11 , wherein converting at least a portion of the one or more platinum-group metal layers to a transition metal/platinum-group metal layer on the platinum-group metal layer to form a platinum-group metal region comprises converting at least a portion of the one or more platinum-group metal layers to a transition metal/platinum-group metal layer that exhibits a chemical composition that transitions between a chemical composition of the transition metal region and a chemical composition of the platinum-group metal region.

Assignees

• Battelle Energy Alliance Llc

Inventors

• Tripathy Prabhat K

Classifications

• C25D3/50

  of platinum group metals · CPC title

• C25D3/665

  from ionic liquids · CPC title

• C25D5/50

  by heat-treatment · CPC title

• C25D5/10 Primary

  Electroplating with more than one layer of the same or of different metals (for bearings C25D7/10) · CPC title