Multi-Layer Coating System for Corrosion Protection of Magnesium Cylinder Block Against Coolant

Patent metadata

Field	Value
Publication number	US-2016268610-A1
Application number	US-201514643449-A
Country	US
Kind code	A1
Filing date	Mar 10, 2015
Priority date	Mar 10, 2015
Publication date	Sep 15, 2016
Grant date	—

Abstract

A metallic part with improved corrosion resistance includes a metallic substrate that is coated with a metal fluoride layer. A primer layer is disposed over the metal fluoride layer. Finally, the metallic part is over-coated with a polymeric layer that is disposed over the primer layer.

First claim

What is claimed is:

1 . A metallic part with improved corrosion resistance, the metallic part comprising:
a metallic substrate; a metal fluoride layer disposed over the metal or metal alloy substrate; a primer layer disposed over the metal fluoride layer; and a polymeric layer disposed over the primer layer.

2 . The metallic part of claim 1 wherein the metallic fluoride layer has a thickness from about 1 micron to about 1 mm and the primer layer has a thickness from about 5 microns to about 200 microns.

3 . The metallic part of claim 1 wherein the polymeric layer has a thickness from about 500 microns to about 5 mm.

4 . The metallic part of claim 1 wherein the metallic substrate is a magnesium alloy.

5 . The metallic part of claim 4 wherein the magnesium alloy includes from 85 to 99 weight percent magnesium and 1 to 15 weight percent of a component selected from the group consisting of magnesium, aluminum, zinc, manganese, silicon, copper, rare earths and zirconium, yttrium, neodymium, silver, gadolinium, other rare earth metals, and combinations thereof.

6 . The metallic part of claim 1 wherein the primer layer is a metal oxide layer, metal nitride, metal carbide, metal boride, or a ceramic layer.

7 . The metallic part of claim 1 wherein the primer layer includes silica oxide, magnesia, kaolin, montmorillonite, other clays, and combinations thereof.

8 . The metallic part of claim 1 wherein the primer layer includes an oxide of a metal selected from the group consisting of Al, Ca, Zn, Ca, Y, Si, Ti, and alloys thereof.

9 . The metallic part of claim 1 wherein the primer layer is a metal layer or a metal alloy layer.

10 . The metallic part of claim 9 wherein the primer layer includes an alloy selected from the group consisting of an alloy Ni—P, Ni—P—Mo, Ni—Sn—P, Co—P, Co—P—Mo, Ni—B, Ni—B—Ti, Ni—B—Mo, Ni—B—Sn, Co—P, Co—P—W, Co—B, Ni—Cu—P, Cu, Zn, and combinations thereof.

11 . The metallic part of claim 1 wherein the metal fluoride layer is a magnesium difluoride layer.

12 . The metallic part of claim 1 wherein the polymer layer is an acrylic layer.

13 . The metallic part of claim 1 wherein the metallic substrate is positioned within an automobile engine block.

14 . The metallic part of claim 1 wherein the metallic substrate is an automobile engine component.

15 . The metallic part of claim 1 wherein the metallic substrate is a fuel cell component.

16 . A method for forming a metallic part with improved corrosion resistance, the metallic part including a metallic substrate, a metal fluoride layer disposed over the metal or metal alloy substrate, a primer layer disposed over the metal fluoride layer, and a polymeric layer disposed over the primer layer, the method comprising:
forming the metal fluoride layer on the metallic substrate; coating the metal fluoride layer with the primer layer; and coating the primer layer with the polymeric layer.

17 . The method of claim 16 wherein the metal fluoride layer is formed by contacting the metallic substrate with a fluorine containing compound.

18 . The method of claim 16 wherein the primer layer is formed by, electrolytic deposition, chemical vapor deposition, or electroless plating

19 . The method of claim 16 wherein the primer layer is formed from an aqueous metal oxide-containing slurry.

Assignees

• Gm Global Tech Operations Llc

Inventors

• Mcclory Brian J
• Wang Yucong
• Abd Elhamid Mahmoud H

Classifications

• C23C18/1637

  metallic substrate · CPC title

• H01M8/02 Primary

  Details (electrodes H01M4/86 - H01M4/98) · CPC title

• C23C16/08

  from metal halides · CPC title

• C23C16/44

  characterised by the method of coating (C23C16/04 takes precedence) · CPC title

• C23C28/04

  only coatings of inorganic non-metallic material · CPC title