Corrosion and fatigue resistant coating for a non-line-of-sight (nlos) process

Abstract

A non-line-of-sight (NLOS) coating process is provided for a substrate having first and second transverse surfaces where the second surface lacks a LOS for depositional processing. The NLOS coating process includes electroplating or electroless plating a crack-resistant interlayer coating to at least the second surface and applying a wear-resistant coating to the crack-resistant interlayer coating by electrolytic or electroless plating.

What is claimed is: 
     
         1 . A non-line-of-sight (NLOS) coating process for a substrate having first and second transverse surfaces where the second surface lacks a LOS for depositional processing, the NLOS coating process comprising:
 electroplating or electroless plating a crack-resistant interlayer coating to at least the second surface; and   applying a wear-resistant coating to the crack-resistant interlayer coating by electrolytic or electroless plating.   
     
     
         2 . The NLOS coating process according to  claim 1 , wherein the substrate defines a bore-hole and the second surface is an interior facing surface of the bore-hole. 
     
     
         3 . The NLOS coating process according to  claim 1 , wherein:
 the substrate comprises at least one or more of stainless steels, carbon steels, titanium alloys, nickel based superalloys, aluminum alloys and magnesium alloys, and   the crack-resistant interlayer coating has a low elastic modulus and/or a high fracture toughness as compared to the substrate.   
     
     
         4 . The NLOS process according to  claim 1 , wherein the crack-resistant interlayer coating is porous. 
     
     
         5 . The NLOS coating process according to  claim 1 , wherein the crack-resistant interlayer coating comprises at least one of zinc (Zn), tin (Sn), tin-zinc (Sn—Zn), silver (Ag), indium (In), bismuth (Bi), gold (Au), lead (Pb), cadmium (Cd) and aluminum (Al). 
     
     
         6 . The NLOS coating process according to  claim 1 , wherein the electrolytic or electroless plating comprises nickel plating. 
     
     
         7 . The NLOS coating process according to  claim 1 , wherein the wear-resistant coating comprises at least one of chromium (Cr), cobalt phosphorus (Co—P), nickel tungsten (Ni—W), ni (Ni), cobalt (Co), nickel cobalt (Ni—Co), nickel boron (Ni—B) and nickel phosphorus (Ni—P). 
     
     
         8 . The NLOS coating process according to  claim 7 , wherein the wear-resistant coating further comprises boron nitride (BN) or cubic BN, diamonds, chromium carbide (Cr 3 C 2 ) and silicon carbide (SiC). 
     
     
         9 . The NLOS coating process according to  claim 1 , further comprising at least one of:
 interposing a corrosion-resistant coating between the substrate and the crack-resistant interlayer coating; and   interposing the corrosion-resistant coating between the crack-resistant interlayer coating and the wear-resistant coating.   
     
     
         10 . The NLOS coating process according to  claim 9 , wherein:
 where the corrosion-resistant coating is interposed between the substrate and the crack-resistant interlayer coating, the corrosion resistant coating comprises at least one of zinc (Zn), tin (Sn) and tin-zinc (Zn—Sn), and   where the corrosion-resistant coating is interposed between the crack-resistant interlayer coating and the wear-resistant coating, the corrosion-resistant coating comprises at least one of nickel phosphorous (Ni—P), nickel (Ni), Zn, Sn, Sn—Zn and zinc nickel (Zn—Ni).   
     
     
         11 . A non-line-of-sight (NLOS) coating process, comprising:
 providing a substrate having first and second transverse surfaces,   the second surface lacking a LOS for depositional processing;   electroplating or electroless plating a crack-resistant interlayer coating having first and second opposite interfaces proximate to at least the second surface such that the first interface faces the second surface;   applying a wear-resistant coating to the second interface of the crack-resistant interlayer coating by electrolytic or electroless plating; and   at least one of interposing a corrosion-resistant coating between the second surface and the first interface of the crack-resistant interlayer coating and interposing the corrosion-resistant coating between the crack-resistant interlayer coating and the wear-resistant coating.   
     
     
         12 . A coated article, comprising:
 a substrate having first and second transverse surfaces, the second surface lacking a LOS for depositional processing;   a crack-resistant interlayer coating which is electroplated or electroless plated to at least the second surface; and   a wear-resistant coating which is electrolyticly or electrolessly plated to the crack-resistant interlayer coating.   
     
     
         13 . The coated article according to  claim 12 , wherein the substrate defines a bore-hole and the second surface is an interior facing surface of the bore-hole. 
     
     
         14 . The coated article according to  claim 12 , wherein:
 the substrate comprises at least one or more of stainless steels, carbon steels, titanium alloys, nickel based superalloys, aluminum alloys and magnesium alloys, and   the crack-resistant interlayer coating has a low elastic modulus and/or a high fracture toughness as compared to the substrate.   
     
     
         15 . The coated article according to  claim 12 , wherein the crack-resistant interlayer coating is porous. 
     
     
         16 . The coated article according to  claim 12 , wherein the crack-resistant interlayer coating comprises at least one of zinc (Zn), tin (Sn), tin-zinc (Sn—Zn), silver (Ag), indium (In), bismuth (Bi), gold (Au), lead (Pb), cadmium (Cd) and aluminum (Al). 
     
     
         17 . The coated article according to  claim 12 , wherein the wear-resistant coating comprises at least one of chromium (Cr), cobalt phosphorus (Co—P), nickel tungsten (Ni—W), ni (Ni), cobalt (Co), nickel cobalt (Ni—Co), nickel boron (Ni—B) and nickel phosphorus (Ni—P). 
     
     
         18 . The coated article according to  claim 17 , wherein the wear-resistant coating further comprises boron nitride (BN) or cubic BN, diamonds, chromium carbide (Cr 3 C 2 ) and silicon carbide (SiC). 
     
     
         19 . The coated article according to  claim 12 , further comprising at least one of:
 a corrosion-resistant coating interposed between the substrate and the crack-resistant interlayer coating; and   the corrosion-resistant coating interposed between the crack-resistant interlayer coating and the wear-resistant coating.   
     
     
         20 . The coated article according to  claim 19 , wherein:
 where the corrosion-resistant coating is interposed between the substrate and the crack-resistant interlayer coating, the corrosion resistant coating comprises at least one of zinc (Zn), tin (Sn) and tin-zinc (Zn—Sn), and   where the corrosion-resistant coating is interposed between the crack-resistant interlayer coating and the wear-resistant coating, the corrosion-resistant coating comprises at least one of nickel phosphorous (Ni—P), nickel (Ni), Zn, Sn, Sn—Zn and zinc nickel (Zn—Ni).