PASSIVE COATINGS FOR BULK ALUMINUM AND POWDER PIGMENTS

Abstract

Composition and process for preparing corrosion-resistant passive coatings on bulk-aluminum alloys and aluminum powder-pigments; said coatings derived from an acidic aqueous composition consisting essentially of potassium hexafluorozirconate, basic chromium sulfate and potassium tetrafluoroborate.

Claims

1. Process for preparing passive coatings on bulk-aluminum alloys and aluminum-powder pigments having a micro size ranging from about 2.8 to 4.0 microns which comprises coating said aluminum alloys and powder-pigments with an acidic aqueous composition having a pH from about 2.8 to 4.0 and at temperatures ranging from about 120 F. to 200 F. said aqueous composition consisting essentially of from about, in parts by weight per liter of water, 20 to 70 parts of potassium hexafluorozirconate, 15 to 92 parts of basic chromium sulfate and from 0.0 to 1.5 parts of potassium tetrafluoroborate.

2-6. (canceled)

7. Coating composition for metal substrates comprising corrosion-resistant coated aluminum pigments and an effective amount of a film-forming binder selected from the group consisting inorganic and organic polymers, said coated aluminum pigments derived from an aqueous composition consisting essentially of, in parts by weight per liter of water, from about 20 to 70 parts of potassium hexafluorozirconate, from about 15 to 92 parts of basic chromium sulfate and from about 0.0 to 1.5 parts of potassium tetrafluoroborate.

8. The coating composition of claim 7 wherein the film-forming binder is an inorganic polymer.

9. The coating composition of claim 7 wherein the film-forming binder is an organic polymer.

10. The coating composition of claim 8 wherein the inorganic polymer is a silicone.

11. The coating composition of claim 9 wherein the organic polymer is polyacrylate.

12. The coating composition of claim 9 wherein the organic polymer is polyurethane.

13. Process for preparing passive coatings on bulk-aluminum alloys and aluminum-powder pigments having a micro size ranging from about 2.8 to 4.0 microns which comprises coating said aluminum alloys and powder-pigments with an acidic aqueous composition having a pH of about 3.8 at temperatures ranging from about 120 F. to 150 F.; said aqueous composition consisting essentially of from about, in parts by weight per liter of water, 35 grams per liter of potassium hexafluorozirconate, 46 grams per liter of basic chromium sulfate and from 0.0 to 1.5 grams per liter of potassium tetrafluoroborate.

14. Process for preparing passive coatings on bulk-aluminum alloys and aluminum-powder pigments having a micro size ranging from about 2.8 to 4.0 microns which comprises coating said aluminum alloys and powder-pigments with an acidic aqueous composition having a pH of about 2.8 to 4.0 and at temperatures ranging from about 120 F. to 200 F.; said aqueous composition consisting essentially of about, in parts by weight per liter of water, 20 grams per liter of potassium hexafluorozirconate, 15 grams per liter of basic chromium sulfate and 1.0 grams per liter of potassium tetrafluoroborate.

15. Process for preparing passive coatings on bulk-aluminum alloys and aluminum-powder pigments having a micro size ranging from about 2.8 to 4.0 microns which comprises coating said aluminum alloys and powder-pigments with an acidic aqueous composition having a pH from about 3.8 at temperatures ranging from about 120 F. to 200 F.; said aqueous compositions consisting essentially of about, in parts by weight per liter of water, 35 grams per liter parts of potassium hexafluorozirconate, 46 grams per liter of basic chromium sulfate and 0.0 to 1.5 grams per liter of potassium tetrafluoroborate.

16. Process for preparing passive coatings on bulk-aluminum alloys and aluminum-powder pigments having a micro size ranging from about 2.8 to 4.0 microns which comprises coating said aluminum alloys and powder-pigments with an acidic aqueous composition having a pH from about 2.8 to 4.0 at temperatures ranging from about 120 F. to 200 F.; said aqueous composition consisting essentially of about, in parts by weight per liter of water, 20 grams per liter of potassium hexafluorozirconate, 15 grams per liter of basic chromium sulfate and 1.0 grams per liter of potassium tetrafluoroborate.

Description

DESCRIPTION OF DRAWINGS/FIGURES

[0011] FIG. 1 shows 2014-T3 aluminum coated with, from left to right, Surtec 650 (control), Example 4 coating at 0.5 min, Example 4 coating at 1 min, Example 4 coating at 5 min and Example 4 coating at 8 min. Panels are shown after coating and before ASTM B117 neutral salt fog testing.

[0012] FIG. 2 shows from left to right, uncoated 2024-T3 aluminum, Example 4 coating at 5 min and Example 4 coating at 8 min. Panels are shown after coating.

[0013] FIG. 3 shows 2024-T3 aluminum coated with, Surtec 650 (control) ( 3a), Example 4 coating at 0.5 min (3 B), Example 4 coating at 1 min (3c), Example 4 coating at 5 min (3d) and Example 4 coating at 8 min (3e). Panels are shown after 4 weeks ASTM B 117 neutral salt fog exposure.

DETAILED DESCRIPTION

[0014] The invention relates to corrosion-inhibiting coated aluminum powder pigments and film-forming compositions for coating various metal substrates. More specifically, the invention relates to preparing passive coatings on bulk-aluminum alloys and more particularly on aluminum powder-pigments having a micro size ranging from about 1.0 to 200 microns. The coating is derived from a corrosion-resistant aqueous composition having a pH ranging from about 2.8-4.0 at temperatures ranging from about 120 F to 200 F degrees. The passive coating composition consists essentially of, in parts by weight per liter of water, from about 20 to 70 parts of potassium hexafluorozirconate, 15 to 92 parts of chromium sulfate (basic), and from 0.0 parts to about 1.5 parts of potassium tetrafluoroborate.

EXAMPLE 1

[0015] An acidic aqueous solution having a pH ranging from about 2.8 to 4.0 for treating aluminum and aluminum alloys in bulk and high-surface area powder ranging in size from about 1 micrometer (micron) in diameter to about 200 microns in diameter to form a corrosion-resistant coating thereon comprises, per liter of solution, from about 20 grams per liter to 70 grams per liter of potassium hexafluorozirconate, about 15 grams per liter to 92 grams per liter chromium sulfate basic, at a temperature from about 120 Fahrenheit to about 200 Fahrenheit.

EXAMPLE 2

[0016] An acidic aqueous solution having a pH ranging from about 2.8 to 4.0 for treating aluminum and aluminum alloys in bulk and high-surface area powder ranging in size from about 1 micrometer (micron) in diameter to about 200 microns in diameter to form a corrosion-resistant coating thereon comprises, per liter of solution, from about 20 grams per liter of potassium hexafluorozirconate, about 15 grams per liter chromium sulfate basic, and about 1 gram per liter potassium tetrafluoroborate at a temperature from about 120 Fahrenheit to about 200 Fahrenheit.

EXAMPLE 3

[0017] An acidic aqueous solution having a pH of 3.8 for treating aluminum and aluminum alloys in bulk and high-surface area powder ranging in size from about 1 micrometer (micron) in diameter to about 200 microns in diameter to form a corrosion-resistant coating thereon comprises, per liter of solution, from about 35 grams per liter of potassium hexafluorozirconate and about 46 grams per liter chromium sulfate basic, at a temperature from about 120 Fahrenheit to about 150 Fahrenheit.

EXAMPLE 4

[0018] Prior to forming the passive coating on bulk aluminum, the solution from Example 3 was mixed, with pH adjusted to 3.8 using potassium hydroxide after mixing, while temperature was held at 120 Fahrenheit. Before treating the 2024-T3 aluminum test coupons, the coupons were cleaned for 10 minutes in an alkaline phosphate cleaner at about 140 Fahrenheit, double rinsed in cold tap water, immersed in an acidic deoxidizer for 1 minute, and double rinsed in cold tap water. The treated 2024-T3 coupons were then immersed in the passivation solution for 30 seconds to 8 minutes, then removed and double rinsed in cold tap water with a final rinse in deionized water. Coupons were then allowed to air dry at ambient conditions.

EXAMPLE 5

[0019] A passive coating was applied to 2024-T3 aluminum panels per Example 4 and then coating weights obtained by weighing the coupons, stripping the coatings in 50% nitric acid, rinsing and drying and then re-weighing. Table 1 shows the coating weights for coatings formed from the new composition compared to the control, which is described in prior art (U.S. Pat. No. 6,521,029). As the data show, coatings from Example 4 are approximately 2 times heavier (thicker) for a given immersion time compared to the control.

TABLE-US-00001 TABLE 1 Temperature Average (F.) Time Coating weights Coating Process Fahrenheit (minutes) (mg/ft.sup.2) Weight Control 75 5 36.4 35.2 34.8 35.5 (Surtec 150 0.5 17.2 16.8 14.8 16.3 650) 1 20.4 20.8 18.8 20.0 2 22.4 21.2 19.2 20.9 5 35.6 32.0 26.8 31.5 Example 4 120 0.5 32.4 5 55.6

EXAMPLE 6

[0020] The corrosion performance of coatings made from the process described in Example 4 was determined by exposing the treated 2024-T3 panels to ASTM B117 neutral salt fog for 4 weeks. Test panels coated for 0.5, 1, 5 and 8 minutes were assessed. As shown in FIG. 1, the panels coated for 5 and 8 minutes have a significant different appearance or color tint than control. This is an important advantage for quality assurance that the control is lacking. This is even more evident in FIG. 2, which shows the 5 and 8 minute coatings compared to bare aluminum. FIG. 3 shows the same panels after 4 weeks of ASTM B117 neutral salt fog. It is clear that all the Example 4 coatings are outperforming the control, with the 8-minute panel especially high performing. This is also a key advantage over the control, where corrosion performance (resistance to pitting) is limited to about 2 weeks in ASTM B117 neutral salt fog.

[0021] The passive coatings on the aluminum pigments can be added to binders. The binders for the film-forming coatings are selected from the group consisting of inorganic binders such as siloxanes and the organic polymers such as polyurethanes, polyimides, polymers derived from epoxies, polymers derived from isocyanates, and the uncured pre-polymers or monomers of said polymers. Also, the film-forming binders are selected from the group consisting of the inorganic polymers derived from silanes, siloxanes and silicones.

[0022] While this invention has been described by a number of specific examples, it is obvious that there are other variations and modifications which can be made without departing from the spirit and scope of the invention: as particularly set forth in the appended claims.