FIELD OF THE INVENTION
The instant invention relates to a medium for forming a deposit on the
surface of a metallic or conductive surface. The medium
deposits a mineral containing coating or film upon a metallic or
conductive surface.
BACKGROUND OF THE INVENTION
Silicates have been used in electrocleaning operations to clean steel, tin,
among other surfaces. Electrocleaning is typically employed as a cleaning step
prior to an electroplating operation. Using "Silicates As Cleaners In The
Production of Tinplate" is described by L.J. Brown in February 1966 edition of
Plating.
Processes for electrolytically forming a protective layer or film by using an
anodic method are disclosed by U.S. Patent No. 3,658,662 (Casson, Jr. et al.), and
United Kingdom Patent No. 498,485; both of which are hereby incorporated by
reference.
U.S. Patent No. 5,352,342 to Riffe, which issued on October 4, 1994 and is
entitled "Method And Apparatus For Preventing Corrosion Of Metal Structures"
that describes using electromotive forces upon a zinc solvent containing paint.
SUMMARY OF THE INVENTION
The instant invention solves problems associated with conventional
practices by providing a medium for a cathodic method for forming a protective layer upon a
metallic substrate. The cathodic method is normally conducted by immersing a
electrically conductive substrate into a silicate containing bath wherein a current is
pased through the bath and the substrate is the cathode. A mineral layer
comprising an amorphous matrix surrounding or incorporating metal silicate
crystals forms upon the substrate. The mineral layer imparts improved corrosion
resistance, among other properties, to the underlying substrate.
The inventive medium is also a marked improvement
as solvents or solvent containing systems are not required to form a
corrosion resistant layer, i.e., a mineral layer. In contrast, to conventional compositions
the inventive medium is substantially solvent free. By "substantially solvent free"
it is meant that less than about 5 wt.%, and normally less than about 1 wt.%
volatile organic compounds (V.O.C.s) are present in the electrolytic environment.
Conventional electrocleaning processes sought to avoid formation of
oxide containing products such as greenalite whereas the instant invention relates
to a medium for forming a mineral layer.
BRIEF DESCRIPTION OF THE DRAWING
Figure 1 is a schematic drawing of the circuit and apparatus which can be
employed for contacting an embodiment of a medium in accordance with the present invention with a metal surface.
DETAILED DESCRIPTION
The instant invention relates to a medium according to Claim 1.
The medium is employed in a process
an electrically enhanced method to obtain
a mineral coating or film upon a metallic or conductive surface. By "mineral
containing coating," it is meant to refer to a relatively thin coating or film which is
formed upon a metal or conductive surface wherein at least a portion of the coating
or film includes at least one of metal atom containing mineral, e.g., an amorphous
phase or matrix surrounding or incorporating crystals comprising a zinc disilicate.
Mineral and Mineral Containing are defined in the previously identified
Copending and Commonly Assigned Patents and Patent Applications; incorporated
by reference. By "electroyltic" or "electrodeposition" or "electrically enhanced",
it is meant to refer to an environment created by passing an electrical current
through a silicate containing medium while in contact with an electrically
conductive substrate wherein the substrate functions as the cathode.
The electroyltic environment can be established in any suitable manner
including immersing the substrate, applying a silicate containing coating upon the
substrate and thereafter applying an electrical current, among others. The
preferred method for establishing the environment will be determined by the size
of the substrate, electroplating time, among other parameters known in the
electrodeposition art.
The silicate containing medium can be a fluid bath, gel, spray, among other
methods for contacting the substrate with the silicate medium. Examples of the
silicate medium comprise a bath containing at least one alkali silicate, a gel
comprising at least one alkali silicate and a thickener, among others. Normally,
the medium comprises a bath of sodium silicate.
The metal surface refers to a metal article as well as a non-metallic or an
electrically conductive member having an adhered metal or conductive layer.
Examples of suitable metal surfaces comprise at least one member selected from
the group consisting of galvanized surfaces, zinc, iron, steel, brass, copper, nickel,
tin, aluminum, lead, cadmium, magnesium, alloys thereof, among others.
The mineral layer can be formed on a nonconductive
substrate having at least one surface coated with an electrically
conductive material, e.g., a ceramic material encapsulated within a metal.
Conductive surfaces can also include carbon or graphite as well as conductive
polymers (polyaniline for example).
The mineral coating can enhance the surface characteristics of the metal or
conductive surface such as resistance to corrosion, protect carbon (fibers for
example) from oxidation and improve bonding strength in composite materials,
and reduce the conductivity of conductive polymer surfaces including potential
application in sandwich type materials.
In one embodiment of the invention, the silicate medium is modified to
include one or more dopant materials. While the cost and handling characteristics
of sodium silicate are desirable, at least one member selected from the group of
water soluble salts and oxides of tungsten, molybdenum, chromium, titanium,
zircon, vanadium, phosphorus, aluminum, iron, boron, bismuth, gallium, tellurium,
germanium, antimony, niobium (also known as columbium), magnesium and
manganese, mixtures thereof, among others, and usually, salts and oxides of
aluminum and iron can be employed along with or instead of a silicate. The dopant
materials can be introduced to the metal or conductive surface in pretreatment
steps prior to electrodeposition, in post treatment steps following
electrodeposition, and/or by alternating electrolytic dips in solutions of dopants
and solutions of silicates if the silicates will not form a stable solution with the
water soluble dopants. When sodium silicate is employed as a mineral solution,
desirable results can be achieved by using N grade sodium silicate supplied by
Philadelphia Quartz (PQ) Corporation. The presence of dopants in the mineral
solution can be employed to form tailored mineral containing surfaces upon the
metal or conductive surface, e.g, an aqueous sodium silicate solution containing
aluminate can be employed to form a layer comprising oxides of silicon and
aluminum.
The silicate solution can also be modified by adding water soluble
polymers, and the elctrodeposition solution itself can be in the form of a flowable
gel consistency. A suitable composition can be obtained in an aqueous
composition comprising 3 wt% N-grade Sodium Silicate Solution (PQ Corp), 0.5
wt% Carbopol EZ-2 (BF Goodrich), about 5 to 10 wt.% fumed silica, mixtures
thereof, among others . Furthers the aqueous silicate solution can be filled with a
water dispersible polymer such as polyurethane to electro deposit a mineral-polymer
composite coating. The characteristics of the electrodeposition solution
can be modified or tailored by using an anode material as a source of ions which
can be available for codeposition with the mineral anions and/or one or more
dopants. The dopants can be useful for building additional thickness of the
electrodeposited mineral layer.
The following sets forth the parameters which may be employed for
tailoring the process to obtain a desirable mineral containing coating :
1. Voltage 2. Current Density 3. Apparatus or Cell Design 4. Deposition Time 5. Concentration of the N-grade sodium silicate solution 7. Type and concentration of anions in solution 8. Type and concentration of cations in solution 9. Composition of the anode 10. Composition of the cathode 11. Temperature 12. Pressure 13. Type and Concentration of Surface Active Agents
The specific ranges of the parameters above depend on the substrate to be
deposited on and the intended composition to be deposited. Items 1, 2, 7, and 8 can
be especially effective in tailoring the chemical and physical characteristics of the
coating. That is, items 1 and 2 can affect the deposition time and coating thickness
whereas items 7 and 8 can be employed for introducing dopants that impart
desirable chemical characteristics to the coating. The differing types of anions and
cations can comprise at least one member selected from the group consisting of
Group I metals, Group II metals, transition and rare earth metal oxides, oxyanions
such as mineral, molybdate, phosphate, titanate, boron nitride, silicon carbide,
aluminum nitride, silicon nitride, mixtures thereof, among others.
The x-ray photoelectron spectroscopy (ESCA) data in the following
Examples demonstrate the presence of a unique metal disilicate species within the
mineralized layer, e.g., ESCA measures the binding energy of the photoelectrons
of the atoms present to determine bonding characteristics.
The following Examples are provided to illustrate certain aspects of the
invention and it is understood that such an Example does not limit the scope of the
invention as defined in the appended claims.
EXAMPLE 1
The following apparatus and materials were employed in this Example:
Standard Electrogalvanized Test Panels, ACT Laboratories 10% (by weight) N-grade Sodium Mineral solution 12 Volt EverReady battery 1.5 Volt Ray-O-Vac Heavy Duty Dry Cell Battery Triplett RMS Digital Multimeter 30 µF Capacitor 29.8 kΩ Resistor
A schematic of the circuit and apparatus which were employed for
practicing the Example are illustrated in Figure 1. Referring now to Figure 1, the
aforementioned test panels were contacted with a solution comprising 10% sodium
mineral and deionized water. A current was passed through the circuit and
solution in the manner illustrated in Figure 1. The test panels was exposed for 74
hours under ambient environmental conditions. A visual inspection of the panels
indicated that a light-grey colored coating or film was deposited upon the test
panel.
In order to ascertain the corrosion protection afforded by the mineral
containing coating, the coated panels were tested in accordance with ASTM
Procedure No. B 117. A section of the panels was covered with tape so that only
the coated area was exposed and. thereafter, the taped panels were placed into salt
spray. For purposes of comparison, the following panels were also tested in
accordance with ASTM Procedure No. B117, 1) Bare Electrogalvanized Panel,
and 2) Bare Electrogalvanized Panel soaked for 70 hours in a 10% Sodium
Mineral Solution. In addition, bare zinc phosphate coated steel panels(ACT B952,
no Parcolene) and bare iron phosphate coated steel panels (B1000, no Parcolene)
were subjected to salt spray for reference.
The results of the ASTM Procedure are listed in the Table below:
Panel Description | Hours in B117 Salt Spray |
Zinc phosphate coated steel | 1 |
Iron phosphate coated steel | 1 |
Standard Bare Electrogalvanize Panel | ≈ 120 |
Standard Panel with Sodium Mineral Soak | ≈ 120 |
Coated Cathode of the Invention | 240+ |
The above Table illustrates that the instant invention forms a coating or film
which imparts markedly improved corrosion resistance. It is also apparent that the
process has resulted in a corrosion protective film that lengthens the life of
electrogalvanized metal substrates and surfaces.
ESCA analysis was performed on the zinc surface in accordance with
conventional techniques and under the following conditions:
Analytical conditions for ESCA:
Instrument |
Physical Electronics Model 5701 LSci |
X-ray source |
Monochromatic aluminum |
Source power |
350 watts |
Analysis region |
2 mm X 0.8 mm |
Exit angle |
50° |
Electron acceptance angle |
±7° |
Charge neutralization |
electron flood gun |
Charge correction |
C-(C,H) in C 1s spectra at 284.6 eV |
The silicon photoelectron binding energy was used to characterized the nature of
the formed species within the mineralized layer that was formed on the cathode.
This species was identified as a zinc disilicate modified by the presence of sodium
ion by the binding energy of 102.1 eV for the Si(2p) photoelectron.
EXAMPLE 2
This Example illustrates performing the electrodeposition process
at an increased voltage and current in comparison to Example 1.
Prior to the electrodeposition, the cathode panel was subjected to
preconditioning process:
1) 2 minute immersion in a 3:1 dilution of Metal Prep 79 (Parker Amchem), 2) two deionized rinse, 3) 10 second immersion in a pH 14 sodium hydroxide solution, 4) remove excess solution and allow to air dry, 5) 5 minute immersion in a 50% hydrogen peroxide solution, 6) Blot to remove excess solution and allow to air dry.
A power supply was connected to an electrodeposition cell consisting of a
plastic cup containing two standard ACT cold roll steel (clean, unpolished) test
panels. One end of the test panel was immersed in a solution consisting of 10% N
grade sodium mineral (PQ Corp.) in deionized water. The immersed area (1 side)
of each panel was approximately 8 cm by 10 cm (80 cm2)(3 inches by 4 inches (12 sq. in.)) for a 1:1 anode
to cathode ratio. The panels were connected directly to the DC power supply and a
voltage of 6 volts was applied for 1 hour. The resulting current ranged from
approximately 0.7-1.9 Amperes. The resultant current density ranged from 0.008-0.02 amps/cm (0.05-0.16
amps/in2).
After the electrolytic process, the coated panel was allowed to cry at
ambient conditions and then evaluated for humidity resistance in accordance with
ASTM Test No. D2247 by visually monitoring the corrosion activity until
development of red corrosion upon 5% of the panel surface area. The coated test
panels lasted 25 hours until the first appearance of red corrosion and 120 hours
until 5% red corrosion. In comparison, conventional iron and zinc phosphated
steel panels develop first corrosion and 5% red corrosion after 7 hours in ASTM
D2247 humidity exposure. The above Examples, therefore, illustrate that the
inventive process offers an improvement in corrosion resistance over iron and zinc
phosphated steel panels.
EXAMPLE 3
Two lead panels were prepared from commercial lead sheathing and
cleaned in 6M HCl for 25 minutes. The cleaned lead panels were subsequently
placed in a solution comprising 1 wt.% N-grade sodium silicate (supplied by PQ
Corporation).
One lead panel was connected to a DC power supply as the anode and the
other was a cathode. A potentional of 20 volts was applied initially to produce a
current ranging from 0.9 to 1.3 Amperes. After approximately 75 minutes the
panels were removed from the sodium silicate solution and rinsed with deionized
water.
ESCA analysis was performed on the lead surface. The silicon
photoelectron binding energy was used to characterized the nature of the formed
species within the mineralized layer. This species was identified as a lead
disilicate modified by the presence of sodium ion by the binding energy of 102.0
eV for the Si(2p) photoelectron.
EXAMPLE 4
This Example demonstrates forming a mineral surface upon an aluminum
substrate. Using the same apparatus in Example 1, aluminum coupons (3" x 6")
were reacted to form the metal silicate surface. Two different alloys of aluminum
were used, A1 2024 and A17075. Prior to the panels being subjected to the
electrolytic process, each panel was prepared using the methods outlined below in
Table A. Each panel was washed with reagent alcohol to remove any excessive
dirt and oils. The panels were either cleaned with Alumiprep 33, subjected to
anodic cleaning or both. Both forms of cleaning are designed to remove excess
aluminum oxides. Anodic cleaning was accomplished by placing the working
panel as an anode into an aqueous solution containing 5% NaOH, 2.4% Na2CO3,
2% Na2SiO3, 0.6% Na3PO4, and applying a potential to maintain a current
density of 100mA/cm2 across the immersed area of the panel for one minute.
Once the panel was cleaned, it was placed in a 1 liter beaker filled with 800
mL of solution. The baths were prepared using deionized water and the contents
are shown in the table below. The panel was attached to the negative lead of a DC
power supply by a wire while another panel was attached to the positive lead. The
two panels were spaced 5 cm(2inches) apart from each other. The potential was set to
the voltage shown on the table and the cell was run for one hour.
Example | A | B | C | D | E | F | G | H |
Alloy type | 2024 | 2024 | 2024 | 2024 | 7075 | 7075 | 7075 | 7075 |
Anodic | Yes | Yes | No | No | Yes | Yes | No | No |
Cleaning |
Acid Wash | Yes | Yes | Yes | Yes | Yes | Yes | Yes | Yes |
Bath Solution |
Na2SiO3 | 1% | 10% | 1% | 10% | 1% | 10% | 1% | 10% |
H2O2 | 1% | 0% | 0% | 1% | 1% | 0% | 0% | 1% |
Potential | 12V | 18V | 12V | 18V | 12V | 18V | 12V | 18V |
ESCA was used to analyze the surface of each of the substrates. Every
sample measured showed a mixture of silica and metal silicate. Without wishing
to be bound by any theory or explanation, it is believed that the metal silicate is a
result of the reaction between the metal cations of the surface and the alkali
silicates of the coating. It is also believed that the silica is a result of either excess
silicates from the reaction or precipitated silica from the coating removal process.
The metal silicate is indicated by a Si (2p) binding energy (BE) in the low 102 eV
range, typically between 102.1 to 102.3. The silica can be seen by Si(2p) BE
between 103.3 to 103.6 eV. The resulting spectra show overlapping peaks, upon
deconvolution reveal binding energies in the ranges representative of metal silicate
and silica.
EXAMPLE 5
This Example illustrates an alternative to immersion for creating the silicate
containing medium.
An aqueous gel made from 5% sodium silicate and 10% fumed silica was
used to coat cold rolled steel panels. One panel was washed with reagent alcohol,
while the other panel was washed in a phosphoric acid based metal prep, followed
by a sodium hydroxide wash and a hydrogen peroxide bath. The apparatus was set
up using a DC power supply connecting the positive lead to the steel panel and the
negative lead to a platinum wire wrapped with glass wool. This setup was
designed to simulate a brush plating operation. The "brush" was immersed in the
gel solution to allow for complete saturation. The potential was set for 12V and
the gel was painted onto the panel with the brush. As the brush passed over the
surface of the panel, hydrogen gas evolution could be seen. The gel was brushed
on for five minutes and the panel was then washed with DI water to remove any
excess gel and unreacted silicates.
ESCA was used to analyze the surface of each steel panel. ESCA detects
the reaction products between the metal substrate and the environment created by
the electrolytic process. Every sample measured showed a mixture of silica and
metal silicate. The metal silicate is a result of the reaction between the metal
cations of the surface and the alkali silicates of the coating. The silica is a result of
either excess silicates from the reaction or precipitated silica from the coating
removal process. The metal silicate is indicated by a Si (2p) binding energy (BE)
in the low 102 eV range, typically between 102.1 to 102.3. The silica can be seen
by Si(2p) BE between 103.3 to 103.6 eV. The resulting spectra show overlapping
peaks, upon deconvolution reveal binding energies in the ranges representative of
metal silicate and silica.
EXAMPLE 6
Using the same apparatus in Example 1, cold rolled steel coupons (ACT
laboratories) were reacted to form the metal silicate surface. Prior to the panels
being subjected to the electrolytic process, each panel was prepared using the
methods outlined below in Table B. Each panel was washed with reagent alcohol
to remove any excessive dirt and oils. The panels were either cleaned with
Metalprep 79 (Parker Amchem), subjected to anodic cleaning or both. Both forms
of cleaning are designed to remove excess metal oxides. Anodic cleaning was
accomplished by placing the working panel as an anode into an aqueous solution
containing 5% NaOH, 2.4% Na2CO3, 2% Na2SiO3, 0.6% Na3PO4, and applying
a potential to maintain a current density of 100mA/cm2 across the immersed area
of the panel for one minute.
Once the panel was cleaned, it was placed in a 1 liter beaker filled with 800
mL of solution. The baths were prepared using deionized water and the contents
are shown in the table below. The panel was attached to the negative lead of a DC
power supply by a wire while another panel was attached to the positive lead. The
two panels were spaced inches apart from each other. The potential was set to
the voltage shown on the table and the cell was run for one hour.
Example | AA | BB | CC | DD | EE |
Substrate type | CRS | CRS | CRS | CRS | CRS |
Anodic Cleaning | No | Yes | No | No | No |
Acid Wash | Yes | Yes | Yes | No | No |
Bath Solution |
Na2SiO3 | 1% | 10% | 1% | - | - |
Potential (V) | 14-24 | 6 (CV) | 12V (CV) | - | - |
Current Density | 23 (CC) | 23-10 | 85-48 | - | - |
(mA/cm2) B177 | 2hrs | 1 hr | 1 hr | 0.25 hr | 0.25 hr |
The electrolytic process was either run as a constant current or constant
voltage experiment, designated-by the CV or CC symbol in the table. Constant
Voltage experiments applied a constant potential to the cell allowing the current to
fluctuate while Constant Current experiments held the current by adjusting the
potential. Panels were tested for corrosion protection using ASTM B117. Failures
were determined at 5% surface coverage of red rust.
ESCA was used to analyze the surface of each of the substrates. ESCA
detects the reaction products between the metal substrate and the environment
created by the electrolytic process. Every sample measured showed a mixture of
silica and metal silicate. The metal silicate is a result of the reaction between the
metal cations of the surface and the alkali silicates of the coating. The silica is a
result of either excess silicates from the reaction or precipitated silica from the
coating removal process. The metal silicate is indicated by a Si (2p) binding
energy (BE) in the low 102 eV range, typically between 102.1 to 102.3. The silica
can be seen by Si(2p) BE between 103.3 to 103.6 eV. The resulting spectra show
overlapping peaks, upon deconvolution reveal binding energies in the ranges
representative of metal silicate and silica.
EXAMPLE 7
Using the same apparatus in Example 1, zinc galvanized steel coupons
(EZG 60G ACT Laboratories) were reacted to form the metal silicate surface.
Prior to the panels being subjected to the electrolytic process, each panel was
prepared using the methods outlined below in Table C. Each panel was washed
with reagent alcohol to remove any excessive dirt and oils.
Once the panel was cleaned, it was placed in a 1 liter beaker filled with 800
mL of solution. The baths were prepared using deionized water and the contents
are shown in the table below. The panel was attached to the negative lead of a DC
power supply by a wire while another panel was attached to the positive lead. The
two panels were spaced approximately 5 cm (2 inches) apart from each other. The
potential was set to the voltage shown on the table and the cell was run for one
hour.
Example | A1 | B2 | C3 | D5 |
Substrate type | GS | GS | GS | GS |
Bath Solution
Na2SiO3 | 10% | 1% | 10% | - |
Potential (V) | 6 (CV) | 10 (CV) | 18 (CV) | - |
Current Density (mA/cm2) | 22-3 | 7-3 | 142-3 | - |
B177 | 336 hrs | 224 hrs | 216 hrs | 96 hrs |
Panels were tested for corrosion protection using ASTM B117. Failures
were determined at 5% surface coverage of red rust.
ESCA was used to analyze the surface of each of the substrates. ESCA
detects the reaction products between the metal substrate and the environment
created by the electrolytic process. Every sample measured showed a mixture of
silica and metal silicate. The metal silicate is a result of the reaction between the
metal cations of the surface and the alkali silicates of the coating. The silica is a
result of either excess silicates from the reaction or precipitated silica from the
coating removal process. The metal silicate is indicated by a Si (2p) binding
energy (BE) in the low 102 eV range, typically between 102.1 to 102.3. The silica
can be seen by Si(2p) BE between 103.3 to 103.6 eV. The resulting spectra show
overlapping peaks, upon deconvolution reveal binding energies in the ranges
representative of metal silicate and silica.
EXAMPLE 8
Using the same apparatus in Example 1, copper coupons (C 110 Hard,
Fullerton Metals) were reacted to form the metal silicate surface. Prior to the
panels being subjected to the electrolytic process, each panel was prepared using
the methods outlined below in Table D. Each panel was washed with reagent
alcohol to remove any excessive dirt and oils.
Once the panel was cleaned, it was placed in a 1 liter beaker filled with 800
mL of solution. The baths were prepared using deionized water and the contents
are shown in the table below. The panel was attached to the negative lead of a DC
power supply by a wire while another panel was attached to the positive lead. The
two panels were spaced 5 cm (2 inches)apart from each other. The potential was set to
the voltage shown on the table and the cell was run for one hour.
Example | AA1 | BB2 | CC3 | DD4 | EE5 |
Substrate type | Cu | Cu | Cu | Cu | Cu |
Bath Solution |
Na2SiO3 | 10% | 10% | 1% | 1% | - |
Potential (V) | 12 (CV) | 6 (CV) | 6 (CV) | 36 (CV) | - |
Current Density (mA/cm2) | 40-17 | 19-9 | 4-1 | 36-10 | - |
B117 | 11 hrs | 11hrs | 5 hrs | 5 hrs | 2hrs |
Panels were tested for corrosion protection using ASTM B117. Failures
were determined by the presence of copper oxide which was indicated by the
appearance of a dull haze over the surface.
ESCA was used to analyze the surface of each of the substrates. ESCA
allows us to examine the reaction products between the metal substrate and the
environment set up from the electrolytic process. Every sample measured showed
a mixture of silica and metal silicate. The metal silicate is a result of the reaction
between the metal cations of the surface and the alkali silicates of the coating. The
silica is a result of either excess silicates from the reaction or precipitated silica
from the coating removal process. The metal silicate is indicated by a Si (2p)
binding energy (BE) in the low 102 eV range, typically between 102.1 to 102.3.
The silica can be seen by Si(2p) BE between 103.3 to 103.6 eV. The resulting
spectra show overlapping peaks, upon deconvolution reveal binding energies in the
ranges representative of metal silicate and silica.