Functionally Graded Coatings and Claddings for Corrosion and High Temperature Protection

Abstract

The present disclosure describes functionally graded coatings and claddings for corrosion and high temperature protection.

1 . A method for producing a functionally-graded coating, comprising:
 (a) exposing a mandrel or a substrate to be coated to an electrolyte containing one or more metal ions, and containing one or more ceramic particles, polymer particles, pre-ceramic polymer particles, active fillers, or a combination thereof;   (b) applying an electric current and changing in time one or more of: an amplitude of the electrical current, an amplitude of an electrical potential, an electrolyte temperature, a relative concentration of metal ions or particles in the electrolyte, or an electrolyte agitation, to change a ratio of an electrodeposited species; and   (c) promoting growth of the functionally-graded coating until a desired thickness of the coating is achieved, the electrodeposited species being varied throughout the desired thickness of the coating.   
     
     
         2 . (canceled) 
     
     
         3 . The method of  claim 1 , further comprising heat treating the coating to cause partial or complete sintering of a pre-ceramic polymer applied to said mandrel or substrate by said applying of said electric current. 
     
     
         4 . The method of  claim 3 , where the heat treating has a heat treatment temperature between 200 degrees C. to 1300 degrees C. 
     
     
         5 - 6 . (canceled) 
     
     
         7 . The method of  claim 1 , wherein said one or more metal ions are selected from the group consisting of: Ni, Zn, Fe, Cu, Au, Ag, Pd, Sn, Mn, Co, Pb, Al, Ti, Mg, and Cr. 
     
     
         8 . The method of  claim 1 , wherein the ceramic particles are chosen from metal oxides, carbides, nitrides, or combinations thereof. 
     
     
         9 - 12 . (canceled) 
     
     
         13 . The method of  claim 1 ,
 wherein the polymer particles comprise one or more of: epoxy, polyurethane, polyaniline, polyethylene, poly ether ether ketone, polypropylene, and siloxane;   wherein the pre-ceramic polymer particles comprise one or more of: siloxides, silences, silanes, organosilanes, siloxanes, polyhedral oligomeric silsesquioxanes, polydimethylsiloxanes, and polydiphenylsiloxanes; and/or   wherein the active fillers comprise one or more of: titanium disilicide, yittrium disilicide, nickel disilicide, niobium disilicide, tantalum disilicide, vanadium disilicide, chromium disilicide, and molybdenum disilicide.   
     
     
         14 .- 24 . (canceled) 
     
     
         25 . A coating prepared by the method of  claim 1 . 
     
     
         26 . An electrodeposited corrosion-resistant functionally-graded coating, comprising:
 an interior first region of metal; and   an exterior second region of polymer, pre-ceramic polymer, or ceramic,   wherein a non-discrete region is disposed between the first region and the second region, the non-discrete region being a combination of the first region and the second region.   
     
     
         27 . The functionally-graded coating of  claim 26 , wherein said non-discrete region has a monotonically increasing metal concentration gradient. 
     
     
         28 . The functionally-graded coating of  claim 26 , wherein said non-discrete region has a monotonically decreasing metal concentration gradient. 
     
     
         29 . The functionally-graded coating of  claim 26 , wherein said functionally-graded coating is corrosion-resistant or substantially corrosion resistant, is heat resistant or substantially heat resistant, and/or wear resistant or substantially wear resistant. 
     
     
         30 - 31 . (canceled) 
     
     
         32 . The functionally-graded coating of  claim 26 , wherein said metal comprises one or more metal ions selected from the group consisting of:
 Ni, Zn, Fe, Cu, Au, Ag, Pd, Sn, Mn, Co, Pb, Al, Ti, Mg, and Cr.   
     
     
         33 . The functionally-graded coating of  26 , wherein said ceramic comprises one or more metal oxides, carbides, nitrides, or combinations thereof. 
     
     
         34 - 37 . (canceled) 
     
     
         38 . The functionally-graded coating of  claim 26 , wherein the polymer comprises one or more of: epoxy, polyurethane, polyaniline, polyethylene, poly ether ether ketone, polypropylene, and siloxane; and
 wherein the pre-ceramic polymer comprises one or more of: siloxides, silences, silanes, organosilanes, siloxanes, polyhedral oligomeric silsesquioxanes, polydimethylsiloxanes, and polydiphenylsiloxanes.   
     
     
         39 . (canceled) 
     
     
         40 . The functionally-graded coating of  claim 26 , further comprising a first substrate disposed proximate to a second substrate comprising iron, copper, zinc, aluminum, titanium, nickel, chromium, graphite, carbon, cobalt, lead, epoxy, or composites or alloys thereof.