Method for preparing pre-coated, metallic components and components prepared thereby

Abstract

A high-strength, corrosion- and heat-resistant aircraft structural component such as a fastener is prepared by providing a corrosion-resistant stainless steel or heat-resistant superalloy metallic component precursor that is not in its final heat-treated state, and coating with an aluminum-containing, curable polyaromatic phenolic coating material having a non-volatile portion that is predominantly organic and is curable at about the high-strength metallic alloy component's stress equalizing tempering temperature. The coated, high-strength metallic-alloy component is then thermally treated to concurrently impart pre-determined metallurgical properties to the finished, metallic substrate, and cure the organic, aluminum-containing coating.

1 - 22 . (canceled)  
   
   
       23 . A stress equalized high-strength, corrosion-resistant aircraft structural alloy component comprising a coating made from an organic, polyaromatic phenolic resin mixed with at least one plasticizer and an inorganic additive selected from the group consisting of aluminum powder and chromate filler.  
   
   
       24 . The component of  claim 23 , wherein the alloy is a nickel-base alloy selected from the group consisting of Monel 400, Monel K-500, Inconel 600, and Inconel X-750.  
   
   
       25 . The component of  claim 23 , wherein the alloy component is Monel 400.  
   
   
       26 . The component of  claim 23 , wherein the alloy component is A-286.  
   
   
       27 . The component of  claim 23 , wherein the coating material comprises a polyaromatic resin-based compound.  
   
   
       28 . The component of  claim 23 , wherein the coating material is dissolved in a solvent selected from the group consisting of ethanol, toluene, methyl ethyl ketone, and mixtures thereof.  
   
   
       29 . The component of  claim 28 , wherein the coating material comprises a sprayable solution comprising about 30 weight percent ethanol, about 7 weight percent toluene, about 45 weight percent methyl ethyl ketone, about 2 weight percent aluminum powder and about 2 weight percent strontium chromate.  
   
   
       30 . The component of  claim 23 , wherein the coating is applied to the component to a thickness of from about 0.0003 inch to about 0.0005 inch.  
   
   
       31 . A stress equalized high-strength, corrosion-resistant aircraft structural stainless steel alloy component comprising a coating made from an organic, polyaromatic phenolic resin mixed with at least one plasticizer and an inorganic additive selected from the group consisting of aluminum powder and chromate filler.  
   
   
       32 . The component of  claim 31 , wherein the component is made from a material selected from the group consisting of 302, 303, 304, 305, 410, 416, 430, Custom 450, and 17-4PH stainless steels.  
   
   
       33 . The component of  claim 31 , wherein the coating material comprises a polyaromatic compound.  
   
   
       34 . The component of  claim 31 , wherein the coating material is dissolved in a solvent selected from the group consisting of ethanol, toluene, methyl ethyl ketone, and mixtures thereof.  
   
   
       35 . The component of  claim 34 , wherein the coating material comprises a sprayable solution having about 30 weight percent ethanol, about 7 weight percent toluene, about 45 weight percent methyl ethyl ketone, about 2 weight percent aluminum powder and about 2 weight percent strontium chromate.  
   
   
       36 . The component of  claim 31 , wherein the coating is applied to the component to a thickness of from about 0.0003 to about 0.0005 inch.  
   
   
       37 . A high-strength, aircraft structural alloy component prepared according to the method of claim  1 .  
   
   
       38 . A high-strength, aircraft structural nickel-base alloy component prepared according to the method of claim  12 .  
   
   
       39 - 47 . (canceled)  
   
   
       48 . An aircraft comprising an alloy aircraft structural component comprising: 
 an alloy precursor having a pre-determined stress equalizing heat-treatment temperature, said precursor selected from the group consisting of 302, 303, 304, 305, 410, 416, 430, Custom 450, and 17-4PH stainless steels, said stainless steels having a pre-determined heat-treatment temperature; and    a curable, organic coating comprising a polyaromatic phenolic resin mixed with at least one plasticizer, polytetrafluoroethylene and an inorganic additive selected from the group consisting of aluminum powder and chromate filler, said coating material having a non-volatile portion that is curable at about the pre-determined alloy stress equalizing heat-treatment temperature, said coating cured at a temperature sufficient to substantially concurrently cure the coating and heat-treat the alloy precursor.    
   
   
       49 . An aircraft comprising an alloy aircraft structural component comprising: 
 an alloy precursor having a pre-determined stress equalizing heat-treatment temperature, said precursor wherein the alloy precursor is selected from the group consisting of Monel 400, Monel K-500, Inconel 600, Inconel-X750, and A-286, said alloy precursor having a pre-determined heat-treatment temperature; and    a curable, organic coating comprising a polyaromatic phenolic resin mixed with at least one plasticizer, polytetrafluoroethylene and an inorganic additive selected from the group consisting of aluminum powder and chromate filler, said coating material having a non-volatile portion that is curable at about the pre-determined alloy stress equalizing heat-treatment temperature, said coating cured at a temperature sufficient to substantially concurrently cure the coating and heat-treat the alloy precursor.    
   
   
       50 . An aircraft comprising an alloy aircraft structural component comprising: 
 an alloy precursor having a pre-determined stress equalizing heat-treatment temperature, said precursor wherein the alloy precursor is A-286, said alloy precursor having a pre-determined heat-treatment temperature; and    a curable, organic coating comprising a polyaromatic phenolic resin mixed with at least one plasticizer, polytetrafluoroethylene and an inorganic additive selected from the group consisting of aluminum powder and chromate filler, said coating material having a non-volatile portion that is curable at about the pre-determined alloy stress equalizing heat-treatment temperature, said coating cured at a temperature sufficient to substantially concurrently cure the coating and heat-treat the alloy precursor.    
   
   
       51 . The aircraft of  claim 48 , wherein the aircraft structural component is selected from the group consisting of fasteners, fittings, hinges, bearings, gears, struts, and the mechanical structures attached thereto.  
   
   
       52 . The aircraft of  claim 49 , wherein the aircraft structural component is selected from the group consisting of fasteners, fittings, hinges, bearings, gears, struts, and the mechanical structures attached thereto.  
   
   
       53 . The aircraft of  claim 48 , wherein the coating is applied to the component to a thickness of from about 0.0003 inch to about 0.0005 inch.  
   
   
       54 . The aircraft of  claim 49 , wherein the coating is applied to the component to a thickness of from about 0.0003 inch to about 0.0005 inch.