Low stress property modulated materials and methods of their preparation

Abstract

The technology described herein sets forth methods of making low stress or stress free coatings and articles using electrodeposition without the use of stress reducing agents in the deposition process. The articles and coatings can be layered or nanolayered wherein in the microstructure/nanostructure and composition of individual layers can be independently modulated.

1 .- 46 . (canceled) 
     
     
         47 . An article comprising:
 a low stress coating that has less than 400 MPa of stress, the low stress coating comprising at least two nanolayers comprising:
 a first nanolayer comprising a first material having a first composition and a first nanostructure defined by one or more of a first average grain size, a first grain boundary geometry, a first crystal orientation, and a first defect density, wherein the first material comprises a first alloy; and 
 a second nanolayer comprising a second material having a second composition and a second nanostructure defined by one or more of a second average grain size, a second grain boundary geometry, a second crystal orientation, and a second defect density, wherein the second material comprises a second alloy, 
   wherein at least one of the first average grain size is different from the second average grain size, the first grain boundary geometry is different from the second grain boundary, the first crystal orientation is different from the second crystal orientation, the first defect density is different from the second defect density, or a combination thereof.   
     
     
         48 . The article of  claim 47 , wherein the first composition is different than the second composition. 
     
     
         49 . The method of  claim 47 , wherein the stress is less than 300 MPa. 
     
     
         50 . The method of  claim 47 , wherein the stress is less than 200 MPa. 
     
     
         51 . The article of  claim 47 , wherein the first alloy comprises a first mixture of two or more metals and the second alloy comprises a second mixture of the two or more metals. 
     
     
         52 . The article of  claim 51 , wherein at least one of the two or more metals is independently selected from the group consisting of: molybdenum, tungsten, nickel, iron, cobalt, copper, zinc, manganese, platinum, palladium, rhodium, iridium, gold, aluminum, magnesium, and silver. 
     
     
         53 . The article of  claim 51 , wherein the two or more metals are independently selected from the group consisting of: molybdenum, tungsten, nickel, iron, cobalt, copper, zinc, manganese, platinum, palladium, rhodium, iridium, gold, aluminum, magnesium, and silver. 
     
     
         54 . The article of  claim 47 , further comprising a substrate. 
     
     
         55 . The article of  claim 54 , wherein the substrate is solid. 
     
     
         56 . The article of  claim 54 , wherein the substrate is conductive. 
     
     
         57 . The article of  claim 54 , wherein the substrate is porous. 
     
     
         58 . The article of  claim 54 , wherein the substrate is non-conductive. 
     
     
         59 . The article of  claim 47 , wherein the at least two nanolayers comprise a plurality of alternating layers. 
     
     
         60 . The article of  claim 59 , wherein the first nanolayer has a first tensile strength, a first percentage of elongation, a first hardness, a first ductility, and a first impact toughness;
 the second nanolayer has a second tensile strength, a second percentage of elongation, a second hardness, a second ductility, and a second impact toughness; and   at least one of the first tensile strength is different from the second tensile strength, the first percentage of elongation is different from the second percentage of elongation, the first hardness is different from the second hardness, the first ductility is different from the second ductility, and the first impact toughness is different from the second impact toughness.   
     
     
         61 . The article of  claim 59 , wherein the plurality of alternating layers comprises a plurality of first nanolayers comprising the first nanolayer, and a plurality of second nanolayers comprising the second nanolayer. 
     
     
         62 . The article of  claim 61 , wherein the plurality of first nanolayers comprises stress free materials and the plurality of second nanolayers comprises low stress materials. 
     
     
         63 . The article of  claim 61 , wherein the plurality of first nanolayers comprises low stress or stress free materials and the plurality of second nanolayers comprises uncontrolled stress materials. 
     
     
         64 . The article of  claim 47 , wherein the first nanolayer has a grain size ranging from about 0.5 nanometers (nm) to about 100 nm, and the second nanolayer has a grain size greater than 1,000 nm. 
     
     
         65 . The article of  claim 47 , wherein the at least two nanolayers independently have a thickness ranging from about 0.5 nm to about 1,000 nm. 
     
     
         66 . The article of  claim 47 , wherein the at least two nanolayers independently vary in thickness, nanostructure, microstructure, stress, or a combination thereof.