Note: Descriptions are shown in the official language in which they were submitted.
This application is a division of Application No.
452,348 filed on the 18th day of April, 1984.
~ is invention relates to stable thixotropic coating
c~mpositions which are ideally suited for application t~ parts to
05 be coated by dipspinning or dipping. The coated metal parts eY.cel
in performance in that they are highly resistant to severe
atmospheric and other corrosive conditions to which they are
exposed.
The invention also relates to the metal parts coated with
such compositions and to a method for coating metal parts. More
particularly, the invention relates to acid chromate phosphate
aqueous compositions which comprise certain defined aluminas.
It is known that phosphate and chromate/phosphate
coatings are useful to protect metal surfaces. Traditionally the
method of application has been by spraying, dipping or other
methods of application. Because of the relatively fluid nature of
traditional phosphate and chromate/phosphate compositions, there
is a considerable loss and waste of the coating composition and/or
an incomplete coating of more intricate metal parts. Various
attempts to thicken coating compositions such as with diatomaceous
earth have been unsatisfactory. Other additives to coating
compositions (such as phosphate compositions) like hydroxymethyl
cellulose, polyvinyl acetate, modified sugars, latex and other
synthetic organic materials and resins have been unsatisfactory.
When thickeners like alginates, gum or others are used, the
composition must be buf~ered at a high pH to avoid splitting
(scissoring~ the polymeric thickener. Such a higher pH is not
acceptable for the practice of the invention. It is known ~hat
~k
~;~9~
such thickeners are split primarily because of the oxidizing
characteristic of the chromate (dichromate) ions at prevailing low
pH. Those conventional thickeners which are not affected by the
chromate ions merely dilute the composition and adversely affect
its coating characteristics. The present invention uses chromate
at a low pH, and yet the additives (boehmite alumina, fumed
alumina, silica and/or nonionic surfactant) are stable in the
medium.
U.S. Patenk No. 4,683,151, granted July 2a, 1987
discloses a thixotropic coating composition utilizing amorphous
silicas and nonionic surfactants.
U.S. Patent No. 3,856,568, granted December 24, 1974, to
Tanaka, discloses a coating solution containing colloidal silica
which improves iron loss and other properties on oriented silicon
steel sheets.
U.S. Patent No. 2,465,247, granted March 22, 1949, to
McBride discloses the treatment of ferrous, zinc and cadmium metal
surfaces with a paste-like composition to produce a phosphate
coating and a readily removable powdered layer upon drying. The
paste-like composition is produced by supplying a porous silica
aerogel with an aqueous solution capable of pxoducing phosphate
films. An anionic surfactant, an alkyl aryl sulfonate ~like
Naconal*) is also a component of the composition. The coating on
drying has a loose Eluffy aerogel layer that comes off xeadily by
wringing, brushing or with a blast of air.
* Indicates Trademark
~'3~L~3~9
Gilchrist in U.S. Patent No. 3,615,741, granted October
21, 1971, discloses chromium-containing compositions including a
hydrated chromic oxide and a hydrophobic organic acid which
contribute to a thickening or gelling of the product. The product
has an alkaline pH above 7, usually 8 to 9. Kendall in U.S. Patent
No 3,536,629, granted October 27, 1970, discloses a nona~ueous
paint remover which contains pyrogenic silica, in addition to other
traditional components. Ayres in U.S. Patent No. 3,420,715,
granted January 7, 1969, discloses phos;phate coating solutions that
include a nonionic detergent as a cleaning agent which is consumed
entirely.
For quite some time there has been a need to coat metal
parts by what is called the dipspin or Filwhirl methods. In these
methods, the parts are painted in bulk, that is by the basketful,
avoiding time consuming handling of individual pieces. Irregularly
shaped parts such as coils, springs, screws, valves and wheels,
castings, bolts, washers, fasteners, etc. are coated by such
methods. The dipspin coating method reduces application costs
significantly and covers even difficult to reach or normally
inaccessible surfaces. The method eliminates sagging of the finish
and parts need not be hung individually for drying. In the method,
the parts are loaded into a removable work basket and then dipped
into a tank or drum of the coating composition. After immersion,
the ~illed basket is raised, allowed to drain momentarily and then
spun to remove excess coating. It is taken out and the parts
'3~3~t9
dumped onto a screen to dry. The parts can also be dried by
spinnin~ in the machine. Any surplus coating which is thrown off
the parts generally flows through an outlet and is collected and
recycled to the tank. The Filwhirl process is a modification
wherein the basket full of parts to be coated is immersed in a vat
into which a coating composition is pumped to flood the basket,
which is then spun. Because of the relatively fluid nature of
traditional chromate/phosphate compositions, there is a
considerable loss and waste of the coating composition and/or an
incomplete coating on more intricate metal parts when coated by
the dipspin or Filwhirl methods.
This invention provides a coating which is fluid enough
to reach into and/or cover the concave or intricate portions of a
metal part to be coated, and yet not so fluid as to throw off much
of the coating during a spinning cycle so that the part is not
completely coated with the composition. The coating compositions
of the invention satisfy all this requirement. Moreover, they
remain stable, i.e. the components are not oxidized and they do not
significantly settle or classify into various components or layers
for several months at room temperature. The major proportion of
the pigment does remain in suspension and does not settle at the
bottom of the container. This is an important requirement when the
composition is to be used over and over again or when shipped from
the manufacturer to the applicator.
~3~ 39
In accordance with the invention, a particular coating
composition has now been found which is thixotropic and which is
stable, i.e. it does not undergo degradation and does not classify
or separate into its components, upon long storage periods (shelf
stability) under conditions of use. Also, it is ideally suited for
application by the dipspin techni~ue.
It is noteworthy that in accordance with the invention,
a greater latitude is provided in the type of chromate/phosphate
compositions which can be used. For instance, with respect to the
Allen Patent No. 3,248,251, it is not necessary that the phosphate
binder be confined to the various concentrations and other molar
rela~ionships disclosed by that patent. The present invention,
therefore, allows for the use of a large number of and a great
variety of acid binder solutions for making the thixotropic coating
lS compositions. In accordance with the invention, the stable
thixotropic coating composition of the invention comprises, in
addition to the acid binder which comprises phosphate ions and ions
of the group of chromate or molybdate ions, an alumina of the type
defined below.
2~ Moreover, the coated parts, e.g. metal parts, have a
combination of unusual and unique properties in that they are
resistant to corrosive atmospheric conditions, particularly extreme
salt spray exposure, heat exposure and humidity. The coated parts
may be, if desired, further treated such as to render them
Z5 galvanically active. Also top coats, with pigments if desired, may
be applied.
3~9C3
The invention contemplates an acid stable thixotropic
coating composition which comprises a chromate/phosphate aqueous
composition having as an essential ingredient a dispersible natural
or synthetic hydrated alumina havlng a boehmite or pseudoboehmite
crystal lattice. In this invention the term "boehmite" is generic
to and includes "pseudoboehmite", and reference to the ~ormer
includes the latter, unless specifica:lly stated otherwise. Other
ingredients in the composition of the invention are optional. Such
other ingredients include fumed alllmina, certain silicas and
nonion.ic sur~ctants. These are described further below.
The acid thixotropic compositions of the invention are
constituted or made form aqueous solutions which pre~erably contain
phosphate anions and chromate (or dichromate) and/or molybdate
anions. A great variety of such solutions is known for treatment
of metal surfaces. For instance, Kirk and Othmer, Eds.,
Encyclopedia of Chemical Technology, 2nd ed., vol. 18, Interscience
Publishers, a ~ivision of ~ohn Wiley & Sons, Inc., 1969 (pages 292-
303), describes phosphate and chromate coatings. The United States
patent literature describes coating solutions or dispersions for
protective coating of metals, which compositions are suitable for
use as components of the compositions of the invention. Such
suitable compositions are disclosed by Allen (No. 3,248,2Sl);
Braumbaugh (No. 3,869,293); Col~ins (No. 3,248,243); Wydra (No.
3,857,717); Boies (No. 3,081,146); Romig (No. 2,245,60g); Helwig
(No. 3,967,984); Bennetch (No. 3,443,977); Hirst 5No. 3,562,011)
~91~ 3
and others. Other illustrative patents or literature showing
corrosion inhibiting and protective coating compositions of
phosphates, mixtures of phosphates and chromates and/or molybdates
are known to one skilled in the art and further examples it is
believed need not be supplied.
The aluminas which are utilizable in accordance with the
invention to produce the thixotropic compositions are dispersable
hydrated aluminas having the boehmite tor pseudoboehmite) crystal
lattice. The term "dispersable" refers to being capable of beiny
acid dispersed to an ultimate colloidal particle in an aqueous
monoprotic acid medium.
Suitable for the invention are the hydxated aluminas
having a boehmite crystal lattice which are available commercially
under the trade name "Dispural*" by Remet Corporation and under the
trade name "Catapal*" by Conoco Chemicals Company of which
descriptions of their characteristics are as follows~
Catapal Dispural
AlzO~ 74.2% 76.5%
Carbon 0.36~ 0.5%
2~ SiOz 0.008% 0.008%
FezO3 0 005%
Na2O 0.005% 0.004%
S 0.01% 0.005%
Surface area (BET) 280 MZ/gm 320 m2/gm
~ 39
Other suitable aluminas are disclosed in U.S. Patent No. 4,371,513.
To prepare the thixotropic compositions of the invention,
a water/acid dispersion of the hydrated alumina premix is made and
added to a chromate~phosphate composition. In preparing the
dispersion, the amount of alumina utilized is about 1 to about 30%
by weight based on the total dispersion. More preferably, about
10-20% by weight of alumina is dispersed in a mixture of water and
a monoprotic acid. When less than about 1% by weight of the
alumina is used the results are not as satisfactory as one would
want for most application; whereas for most applications over about
30% by we.ight might not be the most economical composition. But
if desired, the dispersion may contain over 30% of the alumina.
The dispersion may have a pH range of about 1.0 to about 4.0,
preferably 3.5 to about 4Ø Usually, this amounts to about 0.1
to about ~.0% by weight of the dispersion of the monoprotic acid,
depending upon the acid utilized. Among the monoprotic acids which
may be utilized are nitric acid, hydrochloric acid, hypophosphorous
acid, acetic acid, propionic acid, latic acid, glycolic acid and
sulfamic acid. Most preferable of these acids are nitric acid,
hypophosphorous acid and acetic acid. The particular acid utilized
should be inert to the substrate on which the coating is placed.
It is especially advantageous to utilize hypophosphorous acid since
a dual thickening effect occurs: 1) the gelling of the dispersed
alumina, and 2) the reduction of the chromate in the
chromate/phosphate binder to gelatinous chromium chromate or
~L ~9~L3~3~
hydroxide by the hypophosphorous acid. This desirable effect
appears to be greater than that contributed by the acid on the
chromate solution alone or the thickening contributed by the
addition of the alumina dispersion. The actual. viscosity of the
; acid/alumina dispersion may cover a wide range. In fact the
dispersions may be water thin or so thick as to have a paste-like
consistency.
It will be noted that viscosity measurements (cp) of the
products dlsclosed here are made with a Brookfield Helipath LVF.
This device measures shear forces along a vertical path throughout
the composition rather than at one location as with other viscosity
measuring devices.
To prepare the thixotropic compositions of the invention,
the water/acid dispersion of the hydrated alumina premix described
above is made and added to the chromate/phosphate composition. In
; the premix dispersion it is believed that the monoprotic acid
disperses the agglomerates of the alumina and that when the
dispersed alumina is added to a solu.tion containing divalent or
trivalent ions or even positive monovalent ions other than H~, the
alumina is caused to gel and a thixotropic mixture is formed. The
pH of the final composition is generally in the range o~ about 0.0
to about 3.0, preferably in the range of l.5 to about 3Ø The
dispersion is added to the chromate/phosphate composition so as to
prepare a coating composition having an alumina content range which
is pre~erably about l to about 10% by weight based on coating
g
t~399
solids, more preferably about 3 to 6%. This results in a final
coating composition which preferably has a viscosity of about 800
to about 50,000 centipoise; a coating having a viscosity range of
about 1,500 to 10,000 centipoise has been found to be desirable
when parts are to be coated by the dipspin method.
It should be noted that an overlap with respect to the
viscosity may exist between the compositions of the invention and
those of the prior art. Highly pigmented compositions of the art
may have viscosity, yet not be thixotropic and/or suitable for dip
or dipspin coating methods.
Although these ranges of pH and viscosity are given as
a guidance, it is contemplated that by varying one or more of the
ingredients of the composition and if more specialized applications
are desirable, there are circumstances in which one skilled in the
art may wish to prepare a thixotropic coating composition where one
or more of the ingredients may be outside of the specified limits.
For instance, it is contemplated that compositions of higher
viscosities will produce ultra thick coatings which, though not as
desirable for metal parts with intricate shapes and forms or
tighter tolerances, are quite suitable for other metal parts to be
coated. It is also contemplated that such higher viscosity
coatings are quite acceptable i~ t~e spinning cycle speed is
measurably increased ~o cr~ate such forces as to liquify and spread
the coating over the surface to be coated even on more intricate
parts.
9~ 3~
On the other hand, if the minim~ viscosity limits for
the compositions are not observed (for instance as with thixotropic
compositions with centipoise below 1,000, such as about 800), the
film formed on the metal part may not be continuous. Where this
is not essential, such lower viscoslty compositions are quite
acceptable too. Because of the procedural leeway allowed in the
dip and dipspin techni~ues, such decrease of viscosity of the
thixotropic coating compositions may also be accommodated by an
adjustment in the rate of withdrawal of the coated metal part,
addition of another spin cycle, or a decrease in the spin time or
speed. Thus it will be seen that it is within the contemplation
of the invention that one skilled in the art may operate outside
of the preferred parameters disclosed above without avoiding the
spirit of the invention.
It has been found to be advantageous but not necessary
to utilize fumed alumina in the compositions of the invention.
When fumed alumina is added to chromate/phosphate compositions, it
has little thickening effect. However, when utilized in
conjunction with the alumina/acidlwater dispersions of the
invention, the fumed alumina aids significantly to producing a
thixotropic coating. The fumed alumina can be added to the
chromate/phosphate composition together with, before ox after the
alumina dispersion without any significant change in the end
result. The amount of fumed alumina to be added to the
chromate/phosphate composition need generally ~ot be more than
99
about 10%, preferably from about 0.25 to about 5% of the total
solids in the coating composition.
An amorphous silica ingredient may also be used in the
coating composition of the invention. It is a substantially
dehydrated, polymerized silica which rnay be considered as a
condensation polymer of silicic acid. Such amorphous silicas are
known. It is generally accepted that the amorphous silicas are
usually categorized as silica gel, precipitated silica, fumed
silica or colloidal silica. For the purpose of this invention it
has been ~ound that the ~umed silica, precipitated silica and
silica gel are ideally suited. The silica should be added to the
chromate/phosphate composition preferably in the range of 0 to 10~
by weight based on the total solids of the composition. To be used
in conjunction with the amorphous silica additions is a water
soluble, acid stable nonionic surfactant. Suitable nonionic
surfactants for use in the invention are disclosed in Kirk and
Othmer, Encyclopedia of Chemical Technology, vol. 19, pages 531-
554, entitled "Nonionic Surfactants". The noniGnics used herein
are adequately stable and inert to the acidic conditions prevailing
in the binder and the compositions of the invention. It is
preferred that the coating compositions contain from about 0.01 to
about 5% by weight and more preferably about 0.02 to 0.6% by weight
of the surfactant based on total solids.
Another group of highly favored thixotropic coating
compositions of the invention are those which contain a reduced
3~3~39
chromium component. Such thixotropic coating compositions have
properties enhanced by the presence of txivalent chromium (reduced
hexavalent chromium) which forms a gel which comprises typically
chromium chromate and/or chromium hydroxide. In accordance with
the invention the soluble hexavalent chromate in the binder is
therefore reduced to trivalent chromium such as Cr(OH), or
Cr~(CrO4),. These trivalent chromium-containing gels contribute to
the reinforcement of the three dimensional network.
In accordance with the invention, the above described
effect can be accomplished with any chromium-reducing reagent.
Suitable for that purpose are hydrogen peroxide, hydrogen peroxide-
generating reagents, phosphoric acid-generating reagents such as
hypophosphorous acid, phosphorous acid or the salts thereof, such
as the alkali metal, alkaline earth metal and the like. Organic
reducing reagents include the alkanols, such as methanol, ethanol,
lsopropanol, and the like, and polyhydric alcohols such as ethylene
glycol, sorbitol and glycerine, or other equivalent xeagents may
be used. Preferred among the reducing reagents are those which do
not produce extraneous ions which would have an adverse reaction
on the other components of the system. For instance, hydrogen
peroxide is a preferred reagent because the by-product is water.
Inorganic and organic peroxides are also suitable. Other preferred
reagents are those which are phosphate-generating or phosphate and
water-generating. As the reduction takes place the pH of the
;25 composition increases.
1~9~ 3~'39
In accordance with the invention there is a class of
thixotropic compositions which is even more preferred. These
thixotropic compositions comprise insoluble particles which are
incorporated in the chromate/phosphate composition. Solid
particulate materials (metals and nonmetals) suitable for admixing
to the composition are known. For instance, see the Allen Patent
No. 3,248,251. Among these inorganic particles are aluminum,
chromium and zinc. Aluminum particles are most preferred. Ideally
the aluminum particles are of a very small size, such as atomized
aluminum. The size preferably does not exceed 50 microns and
ideally is below 10 microns.
Other particulate solid materials which may be added to
the coating composition of the invention include zinc, oxides of
zirconium, beryllium, iron or chromium, the refractory carbides,
nitrides, silicides, or borides, or the alloys thereof. Preferable
among the particulate solid materials is aluminum or aluminum
alloys. Generally, the particulate solid material is of an average
particle size similar to the range given above. When a solid
particulate material is to be a component of the composition, it
is generally preferred that it be admixed at least by the time of
the addition of other components of the invention, particularly the
alumina and/or fumed alumina dispersion.
In accordance with the invention there is therefore made
available an ideal thixotropic coating for intricate metal parts
ideally suited for the dipspin techni~ues. This composition
14
~ 9~t
supercedes bulk process and the plating techniques used heretofore.
It also provides, as disclosed above, very significant savings in
time and in material over, for instance, the spraying process.
As explained above, while the purpose of the invention
is primarily to apply the coatings hy the dipspin process, the
thixotropic coating compositions may also be sprayed ~n, rolled
on, brushed, dipped or flow or coil-coated. When, in accordance
with the invention, the dipspin process is used, the process of
the invention proceeds as described above.
In accordance with the invention any metal may be coated
with the composition of the invention including steel, stainless
steel, aluminum, ti.tanium, i.e. any metal that can be heated to an
appropriate curing temperature, e.g. approximately 525F. 1ikewise
alloys of these metals can be coated. While especially desirable
for coating metal parts, nonmetallic surfaces may be coat~d also,
like plastics, ceramics, fibrous materials, etc.
It should also be noted that the coating or film on the
metal part may be made very uniform such as about 0.5 mil + O~l.
This is particularly advantageous when metal parts are of intricate
design and shape which then need to be fitted together, such as
screws and nuts which need to be threaded together.
In accordance with another aspect of the invention as
has been disclosed above, the coated part may then be further
coated with a top coat to add any desired characteristics such as
increased lubricity, W resistance, light resistance, detorque
~{~ a~
resistance, and a metallic or zinc plated appearance. Yet, parts
so produced in accordance with the invention will have remarkably
greater corrosion resistance and other desirable properties.
Moreover, coated parts produced in accordance with the invention
may also be given a post treatment of an inorganic top coat
containing a ceramic oxlde and other types of pigment thereby
increasing the heat resistance.
Thus, the coated parts produced in accordance with the
invention are ideally suited for application of additional top
coats or post treatments for making them even better suited for the
desired application.
From the above disclosure it will now be appreciated that
a significant contribution has been ma~ in the field of coating
metal or nonmetallic parts.
The following examples are illustrative of the invention
and are not intended to be limiting. It is evident to one skilled
in the art that the ingredients of the various compositions
illustrated, their relative proportions and amounts, as well as
other variables and parameters can be modified while being within
the scope and the contemplation of the invention, and that the
equivalents of what is disclosed herein are also contemplated to
be within the scope of the invention.
16
~X~ 39~3
The following examples are illustrative of the invention and
are not intended to be limiting. It is evident to one skilled in the
art that the ingredients of the various compositions illustrated, their
relative proportions and amounts, as well as other variables and
parameters can be modified while being within the scope and the
contemplation of the invention, and that the e~uivalents of what is
disclosed herein are also contemplated to be within the scope of the
invention.
16a
~ ~ ~3~ . 3
EX~MPLE 1
A coating composition of the invention was prepared by
mixing the following ingredients:
Magnesium oxide 58.2 g
Chromic acid 286.0 g
Phosphoric acid (85~) 856.3 g
Magnesium caLbonate 180.8
Water 2,108.25 g
Aluminum powder 3,103.5 g
(-325 mesh, particle size 5-10 microns)
To 620g of the mixture, 428g of a premixed 10% boehmite
dispersion was added by stirring. The dispersion was prepared as
follows:
Water 477 g
Hypophosphorous acid (50%) 3.6 g
Dispersible boehmite alumina 45 g
,
17
~ <.~3
The composition has the following characteristics:
pH before dispersion addition 1.6 g
viscosity before dispersion addition 966 cp
p~ after dispersion addition 2.2
viscosity after dispersion addition 1,660 cp
Steel parts such as screws and fasteners are coated with
the composition using the dipspin method. The coating ic dried at
175F and then cured at 650~F. To make the coating electrically
conductive, the cured parts are burnished in a blaster using
aluminum oxide grit (or glass beads at low pressure). The coated
parts had excellent resistance to standard salt spray and corrosion
tests.
Similarly, a premixed dispersion may be made utilizing
other monoprotic acids including nitric acid, acetic acid,
propionic acid, lactic acid, glycolic acid and sul~amic acid.
, 18
1L~ 99
EXAMPLE 2
A coating composition of the type disclosed by Allen
(U.S. Patent No. 3,248,251) was prepared. No pigment was added but
hypophosphorous acid was used to part:Lally reduce the chromate.
Magnesium oxide 300 g
Chromic acid 231 g
Phosphoric acid (85%) 1,487.5 g
~luminum hydroxide 57.8 g
Hypophosphorous acid l50%) 18 g
Water 3,050.0 g
To 520g of the mixture, 428g of a 10% alumina dispersion
using nitric acid was added by stirring. The preparation of the
dispersion was as follows:
Water 447 g
Concentrated nitric acid 4.2 g
Dispersible boehmite alumina 45 g
19
Th ~omposition has the follow~ng c~aract:eristics:
pH before dispersion addition 2.15 g
viscosity before dispersion addition 581 cp
pH after dispersion addition 2.6
viscosity after dispersion addition 1,494 cp
The composition may be used for application as a top coat
over coatings like the composition in Example 1. The top coat is
applied by the dipspin method directly on top of the previous
coating. It is dried at 175F and cured at 650F. When used on
various steel parts including fasteners the corrosion resistance
of the coating system is greatly increased.
~XAMPL~ 3
The following is a composition based on that disclosed
by Braumbaugh (U.S. Patent No. 3,869,293):
Magnesium oxide 205.4 g
Chromic acid 263 g
Phosphoric acid (85%) 1,028.5 g
Water 2,297 g
~. ~9~3~3
~luminum powder 1,119.5 g
(-325 mesh, particle size 5-lU
microns, average)
Aluminum/magnesium alloy powder 1,117 g
(70% Al, -325 mesh)
llOg of a 15% DISPURAL*/HNO. dispersion was slowly added
to 620g of the above composition while stirring. The viscosity
increased forrn 581 cp to 1,079 cp. The pH increased from 2.6 to
2.9.
~his composition was applied to steel fasteners using a
dipspin apparatus. The coating was dried at 175~ and cured at
750~'F. A top coat of a suitable organic paint was applied and
cured at 350F. Metal parts coated with the composition were
highly resistant to extreme weathering conditions.
EXA~PLE 4
Example 3 was repeated but 220g of the dispersion were
added. The observed viscosity increase was from 581 cp to 4,482
cp. The pH change was from 2.6 to 2.9.
Metal parts coated with the composition were highly
resistant to extreme weathering conditions. The exposure of the
part to salt spray testing was remarkably improved.
-
*DISPURAL is a trademark of Remet Corporation for aciddispersible alumina monohydrate of the boehmite type.
; 21
EXAMPL~ 5
Example 3 was repeated but 204g of the following 20%
dispersion was substituted:
Water 400 g
Glycolic acid 10 g
Dispersible boe~mite alumina 80 y
l'he dispersion was mixed by blending at high speed or
five minutes. The viscosity was originally 581 cp and increased
to 10,624 cp on addition of the dispersion.
Similarly, a dispersion may be prepared utilizing a
synthetic alumina having a pseudoboehmite crystal lattice.
EXAMPL~ 6
The composition prepared in Example 2 was repeated, but
3.79g of fumed silica and 0.2g nonionic surfactant were
additionally added. The viscosity after adding the dispersion was
1,494 cp. After adding silica and the surfactant the viscosity
increased to 5,~61 cp where it remained stable.
Metal parts coated similar to the process described in
Example 2 were highl, resistant to extremc weathering conditions.
22
.
, .
~C3~ 39
P~L~MPL~ 7
The same binder compositions as in Example 2 was prepared
but lOg of fumed alumina was added along with 104g of the following
dispersion:
Water 350 g
Hypophosphorous acid (50%) 60 g
Dispersible boehmite alumina 80 g
The composition was mixed by blending at high speed for
five minutes and had the following characteristics:
pH before dispersion/alumina addition 2.15 g
viscosity before dispersion/alumina dispersion 581 cp
pH after dispersion/alumina addition 2.65
viscosity after dispersion/alumina addition 4,150 cp
Steel speclmens such as screws and fasteners are dipped
in the coating composition, dried at 175~, and cured at 650~F.
After dipping in a suitable organic top coat and curing at 350~,
the coated specimens have excellent resistance to salt spray and
corrosion tests.
;~ 23
~.~9~ 3
EUAMPLE 8
A coating composition was prepared by mixing the
following ingredients:
Chromic acid 72 y
Phosphoric acid (85%) 170 g
Water 960 g
~luminum powder
~-325 mesh, particle size 5-10 480 g
microns avg.)
No metallic cation is added.
To 528g of the above mixture, 132g of the 20% dispersion
used in Example 7 was added and blended for five minutes. The
viscosity of this composition was 1,079 cp as compared to 664 cp
prior to addition of the dispersion.
1~ EXAMPLE 9
The base coating used in Example 8 was prepared. To 528g
of the coating, 132g of the 20~ boehmite alumina/glycolic acid
dispersion used in Example 5 was added and blended f~r five
24
~ t~9
minutes. The viscosity of the mixture increased from 664 cp to
996 cp.
EXAMPLE 10
A binder composition of the type disclosed by Wydra (U.S.
Patent No. 3,857,717) was prepared as follows:
Water 2,953 g
Phosphoric acid l85%) 843 g
Phosphorous acid 555 g
Chromic acid 697 g
No cations were added but phosphorous acid was used to
react with some of the chromic acid.
428g of the dispersion used in Example 2 was slowly added
to 600g of the above composition. The pH changed from 0.55 to
1.20. The viscosity increased from 581 cp to 1,245 ~p.
.
EXAMPL~ 11
A binder composition of the type disclosed by Allen (U.S.
Patent No. 3,248,251) is prepared a~cording to the following
:
3!39
formula:
Magnesium oxide 72.5 g
Chromic acid 92.0 g
Phosphoric acid (85%) 318 g
Deionized water 805 g
To 512g of this mixture, 428g of the 10% alumina
dispersion used in Example 2 was added by stirring. The mixture
had the followin~ characteristics:
pH before dispersion addition 1.60
viscosity before dispersion addition 415 cp
pH after dispersion addition 2.1
viscosity after dispersion addition 1,328 cp
EXA~PI.~ 12
Example 11 was repeated except the following dispersion
was substituted:
Water 477 g
Concentrated nitric acid 4.2 g
Dispersi~le alumina 45 g
Fumed alumina 5 g
~6
.~ 9~ 9
~ ter addition of the dispersion the pH increased from
1.60 to 2.00 while the viscosity increase was from 415 cp to 1,826
cp, greater than the increase recorded when only dispersible
alumina was used.
EXAMPL~ 13
A coating composition was prepared using the same binder
described in Example 11 and adding 800g of aluminum powder (5-10
micron particles size, avg.) to 1,280g of the binder. The coating
was mixed using a high shear mixer.
To 636g of the coating composition, lOg of fumed alurnina
was added by mechanical stirring. The viscosity increased from 664
cp to 1,743 cp. When 160g of the alumina dispersion described in
Example 7 was added to the coating, the viscosity increase was
1,743 cp to 9,960 cp. Final viscosities of about 10,000 cp were
lS obtained regardless of the mixing order of the aluminas, and
represanted a viscosity level far in excess of that which could be
obtained by either alumina by itself.
The coating composition was used to coat various
fasteners by the dipspin method. The fasteners were placed in the
~20 dipspin centrifuge basket, dipped into a coating vat containing the
composition, removed and spun, spinning off excess coating. The
parts were removed form the basket, dried at 175F, and cured at
650F. A second coat was applied in the same manner. To make the
9~ 9
coating e`].ectrically conductive, the cure parts were burnished in
a blaster usin~ aluminum oxide grit until the coating was
electrically conductive. The coated parts were highly resistant
to extreme weathering conditions.
EX~MPLF 14
,
A coating composition of the type disclosed by Allen
~U.S. Patent No. 3,248,251) was prepared. No pigment was added but
hypophosphorous acid was used to partially reduce the chxomate.
Magnesium oxide 300 g
Chromic acid 231 g
Phosphoric acid (85%) 1,487.5 g
Aluminum hydroxide 57.8 g
Hypophosphorous acid (50%) 18 g
Water 3,446 g
Fumed sllica 72.87 g
Mixed oxide black pigment 790.4 g
The mixture was ball milled 4 hours.
28
9~3~ t
To 580g of the above coating composition, llOg of a 20%
dispexsion was added. The dispersion was made according t'o the
following:
Deionized water 475 g
Dispersible boehmite alumina 25 g
Fumed alumina 75 g
Hypophosphorous acid (50%) 30
The pH of the mixture increased from 2.40 to 2.50. The
viscosity increased from 581 cp to 1,079 cp.
:lO Various steel specimens such as screws and fasteners are
coated with a base coat sirnilar to the one described in Example 13.
When a top coat of this composition is applied to the parts a
coating system is created with remarkably improved resistance to
salt fog corrosion.
Although the present invention has been described with
reference to the most preferred embodiments therein set forth, it
is understood that the present disclosure has been made only by way
of example and the numerous changes in the details of the
compositions may be resorted to without departing from the spirit
and scope of the invention. Thus, the scope of the invention
:should not be limited by the foregoing specification, but rather
only by the scope of the claims appended hereto and the functional
equivalents.
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