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

Patent metadata

Field	Value
Publication number	US-2024376623-A1
Application number	US-202418779578-A
Country	US
Kind code	A1
Filing date	Jul 22, 2024
Priority date	Dec 21, 2021
Publication date	Nov 14, 2024
Grant date	—

Abstract

A metal coated article includes a platinum-group metal region adjacent a refractory metal region, which is adjacent a substrate comprising an inorganic material. A refractory metal carbide layer is adjacent the substrate and the refractory metal layer is adjacent the refractory metal carbide layer. The platinum-group metal region comprises a refractory metal/platinum-group metal layer and a platinum-group metal layer. Related methods are also disclosed.

First claim

1 . A method of forming a metal coated article, comprising:
forming a refractory metal region on a boron-doped diamond substrate, wherein forming the refractory metal region comprises:
depositing a refractory metal from a functional electrolyte in an alkali halide auxiliary electrolyte bath, onto the boron-doped diamond substrate to form a refractory metal layer; and
converting a portion of the refractory metal layer to a refractory metal carbide layer, while a portion of the refractory metal layer remains an unreacted refractory metal, the refractory metal layer on the refractory metal carbide layer;
forming a platinum-group metal region on the refractory metal region, wherein forming the platinum-group metal region comprises:
depositing a platinum-group metal from a functional electrolyte in an alkali halide auxiliary electrolyte bath, onto the refractory metal layer to form a platinum-group metal layer; and
converting a portion of the platinum-group metal layer to a platinum-group metal, refractory metal transition layer between the platinum-group metal layer and the refractory metal layer, the platinum-group metal layer comprising an exterior coating of the metal coated article.

2 . The method of claim 1 , wherein forming the refractory metal region comprises depositing from a functional electrolyte, a layer of tungsten, molybdenum, titanium, vanadium, or a combination thereof.

3 . The method of claim 1 , wherein converting a portion of the refractory metal layer to a refractory metal carbide layer comprises annealing the boron-doped diamond substrate and the refractory metal layer at a temperature from about 500° C. to about 600° C., for a time period range from about 1 hour to about 12 hours, and in an inert-gas environment.

4 . The method of claim 1 , wherein converting a portion of the refractory metal layer to a refractory metal carbide layer comprises annealing the boron-doped diamond substrate after forming the platinum-group metal region, wherein a platinum-group metal, refractory metal transition layer forms between the platinum-group metal layer and the refractory metal layer.

5 . The method of claim 1 , wherein forming the refractory metal region comprises depositing the refractory metal layer from the functional electrolyte at a temperature in a range of about 350° C. to about 500° C.

6 . The method of claim 1 , wherein forming the platinum-group metal region comprises depositing the refractory metal layer from the functional electrolyte at a temperature in a range of about 350° C. to about 500° C.

7 . A method of forming an alloy, comprising:
dissolving an ilmenite concentrate (FeO·TiO 2 ) in an electroplating system: comprising:
a crucible;
a metal salt electrolyte in the crucible;
a working electrode immersed in the metal salt electrolyte;
a reference electrode immersed in the metal salt electrolyte; and
a counter electrode immersed in the metal salt electrolyte, the counter electrode comprising:
a boron-doped diamond substrate;
a refractory metal carbide layer on the boron-doped diamond substrate;
a refractory metal layer on the refractory metal carbide layer; and
a platinum-group layer on a platinum-group metal/refractory metal layer and on the refractory metal carbide layer; and

applying a voltage and a current between the working electrode and the reference electrode, to co-deposit an iron-titanium alloy on a body connected to the working electrode.

8 . The method of claim 7 , wherein the metal salt electrolyte is under an inert atmosphere, and wherein dissolving the ilmenite concentrate releases oxygen into the inert atmosphere and further comprises:
supplying make-up inert gas to the crucible; and
bleeding a portion of the inert atmosphere that includes oxygen.

9 . The method of claim 1 , wherein forming the platinum-group metal region comprises depositing the platinum-group metal from the functional electrolyte in the alkali halide auxiliary electrolyte bath, onto the refractory metal layer to form two or more layers of the platinum-group metal.

10 . The method of claim 1 , wherein forming the platinum-group metal region comprises depositing the platinum-group metal from the functional electrolyte in the alkali halide auxiliary electrolyte bath, onto the refractory metal layer to form three or more layers of the platinum-group metal.

11 . The method of claim 1 , wherein forming the platinum-group metal region comprises depositing the platinum-group metal from the functional electrolyte in the alkali halide auxiliary electrolyte bath, onto the refractory metal layer to form three or more layers of the platinum-group metal, wherein one or more of the three or more layers of the platinum group metal comprises a different platinum-group metal.

12 . The method of claim 1 , wherein forming the platinum-group metal region comprises depositing the platinum-group metal from the functional electrolyte in the alkali halide auxiliary electrolyte bath, onto the refractory metal layer to form three or more layers of the platinum-group metal, wherein two layers of the three or more layers of the platinum-group metal comprises the same platinum-group metal.

13 . A method of forming a metal coated article, comprising:
forming a refractory metal region on a boron-doped diamond substrate, the refractory metal region having a thickness of from about 10 micrometers to about 20 micrometers, wherein forming the refractory metal region comprises:
depositing a refractory metal from a functional electrolyte in an alkali halide auxiliary electrolyte bath, onto the boron-doped diamond substrate to form a refractory metal layer; and
converting a portion of the refractory metal layer to a refractory metal carbide layer, while a portion of the refractory metal layer remains an unreacted refractory metal, the refractory metal layer on the refractory metal carbide layer;
forming a platinum-group metal region on the refractory metal region, wherein forming the platinum-group metal region comprises:
depositing a platinum-group metal from a functional electrolyte in an alkali halide auxiliary electrolyte bath, onto the refractory metal layer to form a platinum-group metal layer; and
converting a portion of the platinum-group metal layer to a platinum-group metal, refractory metal transition layer between the platinum-group metal layer and the refractory metal layer, the platinum-group metal layer comprising an exterior coating of the metal coated article.

14 . The method of claim 13 , wherein converting the portion of the refractory metal layer to the refractory metal carbide layer, while the portion of the refractory metal layer remains the unreacted refractory metal, comprises:
converting the portion of the refractory metal layer to the refractory metal carbide layer wherein the refractory metal carbide layer exhibits a relatively greater thickness than a thickness of the refractory metal layer.

15 . The method of claim 13 , wherein converting the portion of the refractory metal layer to the refractory metal carbide layer, while the portion of the refractory metal layer remains the unreacted refractory metal, comprises:
converting the portion of the refractory metal layer to the refractory metal carbide layer wherein the refractory metal carbide layer exhibits a greater thickness by a ratio of about 3:1 than a thickness of the refractory metal layer.

16 . The method of claim 13 , wherein depositing the platinum-group metal from the functional electrolyte in the alkali halide auxiliary electrolyte bath, onto the refractory metal layer to form the pla

Assignees

• Battelle Energy Alliance Llc

Inventors

• Tripathy Prabhat K

Classifications

• Y10T428/12875

  Platinum group metal-base component · CPC title

• C25D5/50

  by heat-treatment · CPC title

• C25D5/003

  Electroplating using gases, e.g. pressure influence · CPC title

• C25D17/007

  Current directing devices · CPC title

• C25D17/06

  Suspending or supporting devices for articles to be coated · CPC title