Methods for preparing anti-friction coatings

Patent metadata

Field	Value
Publication number	US-2016130519-A1
Application number	US-201414534331-A
Country	US
Kind code	A1
Filing date	Nov 6, 2014
Priority date	Nov 6, 2014
Publication date	May 12, 2016
Grant date	—

Abstract

An article comprises a substrate; a coating comprising a carbon composite; and a binding layer disposed between the substrate and the coating. The carbon composite comprises carbon and a binder containing one or more of the following: SiO 2 ; Si; B; B 2 O 3 ; a metal; or an alloy of the metal; and the metal comprises one or more of the following: aluminum; copper; titanium; nickel; tungsten; chromium; iron; manganese; zirconium; hafnium; vanadium; niobium; molybdenum; tin; bismuth; antimony; lead; cadmium; or selenium.

First claim

What is claimed is:

1 . An article comprising
a substrate; a coating comprising a carbon composite; and a binding layer disposed between the substrate and the coating; wherein the carbon composite comprises carbon and a binder containing one or more of the following: SiO 2 ; Si; B; B 2 O 3 ; a metal; or an alloy of the metal; and the metal comprises one or more of the following: aluminum; copper; titanium; nickel; tungsten; chromium; iron; manganese; zirconium; hafnium; vanadium; niobium; molybdenum; tin; bismuth; antimony; lead; cadmium; or selenium.

2 . The article of claim 1 , wherein the substrate comprises one or more of the following: a metal; an alloy of the metal; or ceramics.

3 . The article of claim 2 , wherein the metal in the substrate comprises one or more of the following: magnesium; aluminum; titanium; manganese; iron; cobalt; nickel; copper; molybdenum; tungsten; palladium; chromium; ruthenium; gold; silver; zinc; zirconium; vanadium; or silicon.

4 . The article of claim 1 , wherein the binding layer comprises one or more of the following: a solid solution of the binder in the carbon composite and the substrate; a material that is included in both the binder of the carbon composite and the substrate; or a solder.

5 . The article of claim 1 , wherein the coating has a thickness of about 5 μm to about 10 mm.

6 . The article of claim 1 , wherein the binding layer has a thickness of about 50 nm to about 2 mm.

7 . The article of claim 1 , wherein the coating comprises one or more carbon composite foils.

8 . The article of claim 1 , wherein the carbon composite comprises at least two carbon microstructures; and a binding phase disposed between the at least two carbon microstructures; and wherein the binding phase comprises the binder.

9 . The article of claim 8 , wherein the binding phase comprises a binder layer and an interface layer bonding one of the at least two carbon microstructures to the binder layer, wherein the interface layer comprises at least one of the following: a C-metal bond; a C—B bond; a C—Si bond; a C—O—Si bond; a C—O-metal bond; or a metal carbon solution.

10 . The article of claim 1 , wherein the carbon composite comprises graphite.

11 . The article of claim 1 , wherein the article is a coated bearing, a coated pipeline, a coated valve, a coated piston, or a coated shaft.

12 . A method for coating a substrate, the method comprising:
disposing a coating on a substrate, the coating comprising a carbon composite foil; and binding the coating to the substrate; wherein the carbon composite foil comprises carbon and a binder; the binder comprises one or more of the following: SiO 2 ; Si; B; B 2 O 3 ; a metal; or an alloy of the metal; and the metal comprises one or more of the following: aluminum; copper; titanium; nickel; tungsten; chromium; iron; manganese; zirconium; hafnium; vanadium; niobium; molybdenum; tin; bismuth; antimony; lead; cadmium; or selenium.

13 . The method of claim 12 , wherein binding the coating to the substrate comprises heating the coating and the substrate to form a binding layer between the coating and the substrate.

14 . The method of claim 13 , further comprising pressing the coating and the substrate together during heating.

15 . The method of claim 12 , wherein binding the coating to the substrate comprises heating the coating and a surface of the substrate that the coating is disposed on by one or more of the following: direct current heating; induction heating; microwave heating; or spark plasma sintering.

16 . The method of claim 15 , further comprising pressing the coating and the substrate together during heating.

17 . The method of claim 12 , wherein the method further comprises disposing a solder between the coating and the substrate; applying heat to the solder; and binding the coating to the substrate.

18 . The method of claim 17 , further comprising pressing the coating and the substrate together while applying heat to the solder.

19 . The method of claim 12 , comprising laminating an activation layer to the carbon composite layer to form a coating, disposing the coating on the substrate so that the activation layer is positioned between the carbon composite foil and the substrate; and exposing the activation foil to a selected form of energy to bind the coating to the substrate.

20 . The method of claim 12 further comprising disposing an activation foil between a substrate and the coating; and exposing the activation foil to a selected form of energy to bind the coating to the substrate.

21 . The method of claim 20 , further comprising pressing the coating, the activation foil, and the substrate together while exposing the activation foil to a selected form of energy.

22 . The method of claim 20 , wherein the selected form of energy is one or more of the following: electric current; an electromagnetic radiation; or heat.

23 . The method of claim 20 , wherein the activation foil comprises one or more of the following: a thermite; Al—Ni; Ti—Si; Ti—B; Zr—Si, Zr—B; Ti—Al; Ni—Mg; or Mg—Bi.

24 . The method of claim 23 , wherein the thermite comprises a reducing agent and an oxidization agent; wherein the reducing agent comprises one or more of the following: aluminum; magnesium; calcium; titanium; zinc; silicon; or boron; and the oxidizing agent comprises one or more of the following: boron oxide; silicon oxide; chromium oxide; manganese oxide; iron oxide; copper oxide; or lead oxide.

Assignees

• Zhao Lei
• Xu Zhiyue
• Baker Hughes Inc

Inventors

• Zhao Lei
• Xu Zhiyue

Classifications

• C10N2050/08

  Solids · CPC title

• B32B2307/554

  Wear resistance · CPC title

• B32B2255/20

  Inorganic coating · CPC title

• B05D2202/00

  Metallic substrate · CPC title

• C10M2201/053

  used as base material · CPC title