Abstract:
The invention relates to a process for forming coatings or free-standing deposits of nanocrystalline metals, metal alloys or metal matrix composites. The process employs drum plating or selective plating processes involving pulse electrodeposition and a non-stationary anode or cathode. Novel nanocrystalline metal matrix composites and micro components are disclosed as well. Also described is a process for forming micro components with grain sizes below 1,000nm.
Abstract:
A surface treatment process for enhancing the resistance to intergranular corrosion and intergranular cracking of components fabricated from austenitic Ni-Fe-Cr based alloys comprising the application of surface deformation to the component, to a depth in the range of 0.01 mm to 0.5 mm, for example by high intensity shot peening below the recrystallization temperature, followed by recrystallization heat treatment, preferably at solutionizing temperatures. The surface deformation and annealing process can be repeated to further optimize the microstructure of the near-surface region. Following the final heat treatment, the process optionally comprises the application of further surface deformation (work) of reduced intensity, yielding a worked depth of between 0.005 mm to 0.01 mm, to impart residual compression in the near surface region to further enhance cracking resistance.
Abstract:
Lead and lead-alloy anodes for electrowinning metals such as zinc, copper, lead, tin, nickel and manganese from sulfuric acid solutions, whereby the electrodes are processed by a repetitive sequence of cold deformation and recrystallization heat treatment, within specified limits of deformation, temperature and annealing time, to achieve an improved microstructure consisting of a high frequency of special low Σ CSL grain boundaries (i.e. ⊃50 %). The resultant electrodes possess significantly improved resistance to intergranular corrosion, and yield (1) extended service life, (2) the potential for reduction in electrode thickness with a commensurate increase in the number of electrodes per electrowinning cell, and (3) the opportunity to extract higher purity metal product.
Abstract:
Metal-coated polymer articles containing structural substantially porosity-free, fine-grained and/or amorphous metallic coatings/layers optionally containing solid particulates dispersed therein on polymer substrates, are disclosed. The substantially porosity-free metallic coatings/layers/patches are applied to polymer or polymer composite substrates to provide, enhance or restore vacuum/pressure integrity and fluid sealing functions. Due to the excellent adhesion between the metallic coating and the polymer article satisfactory thermal cycling performance is achieved. The invention can also be employed as a repair/refurbishment technique. The fine-grained and/or amorphous metallic coatings are particularly suited for strong and lightweight articles, precision molds, sporting goods, aerospace and automotive parts and other components exposed to thermal cycling and stress created by erosion and impact damage.
Abstract:
Polycrystalline materials are prepared by electrodeposition of a precursor material that is subsequently heat-treated to induce at least a threefold increase in the grain size of the material to yield a relatively high fraction of 'special' low Σ grain boundaries and a randomized crystallographic texture. The precursor metallic material has sufficient purity and a fine-grained microstructure (e.g., an average grain size of 4 nm to 5 µm). The resulting metallic material is suited to the fabrication of articles requiring high mechanical or physical isotropy and/or resistance to grain boundary-mediated deformation or degradation mechanisms.
Abstract:
Lightweight articles comprising a polymeric material at least partially coated with a fine-grained metallic material are disclosed. The fine-grained metallic material has an average grain size of 2nm to 5,000nm, a thickness between 25 micron and 5cm, and a hardness between 200VHN and 3,000 VHN. The lightweight articles are strong and ductile and exhibit high coefficients of restitution and a high stiffness and are particularly suitable for a variety of applications including aerospace and automotive parts, sporting goods, and the like.
Abstract:
A process for enhancing chemical stability and corrosion resistance is described for perforated current collectors made by continuous production processes for use in electrochemical cells, including storage batteries such as lead-acid batteries. The process relies on utilizing a strip processing method, selected from the group of reciprocating expansion, rotary expansion and punching, to perforate the solid metal strip to form a grid or mesh, as a deformation treatment. The perforation- deformation treatment is followed in rapid succession by a heat-treatment to obtain a recrystallized microstructure in the current collector and optionally by quenching to rapidly reduce the temperature to below approximately 80 °C. The process yields an improved microstructure consisting of a high frequency of special low Σ CSL grain boundaries (⊃ 50 %), exhibiting significantly improved resistance to intergranular corrosion and cracking. Perforated current collectors produced with this process from a solid lead-alloy strip exhibit superior growth and corrosion properties when employed as positive grids in a lead-acid battery.