# US 2014/0191163 A1 · Method of applying a magnesium-containing powder to the surface of an aluminum or aluminum alloy substrate

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- Number: US 2014/0191163 A1
- Document ID: US20140191163A1
- Status: Published application
- Kind: A1
- Application number: 14/030,479
- Filed: 2013-09-18
- Published: 2014-07-10
- Earliest claimed: 2003-11-13
- Assignees: NDSU Research Foundation
- Applicants: Ndsu Research Foundation
- Inventors: Gordon P. BIERWAGEN; Michael E. NANNA; Dante BATTOCCHI
- Web page: https://patentgrep.com/patent/US20140191163A1

## CPC

- C23F 11/182: {Sulfur, boron or silicon containing compounds}
- B05D 3/102: {Pretreatment of metallic substrates (C23C takes precedence)}
- B05D 5/00: Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
- B05D 7/14: to metal, e.g. car bodies (involving a chemical reaction between the metal and the coating C23)
- B05D 7/16: using synthetic lacquers or varnishes
- C08G 18/10: Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
- C08G 18/2865: {Compounds having only one primary or secondary amino group; Ammonia}
- C08G 18/289: {containing silicon}
- C08G 18/58: Epoxy resins {(C08G18/42, C08G18/48 take precedence; reaction products of epoxy resins with at least equivalent amounts of compounds containing active hydrogen C08G18/6407, with at least equivalent amounts of amines C08G18/6415; polymeric products of isocyanates or isothiocyanates with epoxy compounds having no active hydrogen C08G18/003)}
- C08G 18/792: {formed by oligomerisation of aliphatic and/or cycloaliphatic isocyanates or isothiocyanates}
- C09D 5/10: containing metal dust
- C09D 163/00: Coating compositions based on epoxy resins; Coating compositions based on derivatives of epoxy resins
- C09D 175/02: Polyureas
- C09D 175/04: Polyurethanes
- B05D 1/185: {applying monomolecular layers (B05D1/204 takes precedence)}
- B05D 7/54: {No clear coat specified}
- B05D 2202/25: based on Al
- B05D 2601/20: used for non-pigmentation effect
- C08G 2150/90: Compositions for anticorrosive coatings
- C08G 2270/00: Compositions for creating interpenetrating networks
- C08K 3/08: Metals
- C23F: NON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE (working metal by laser beams B23K26/00; desurfacing by applying flames B23K7/00; working of metal by electro-erosion B23H; producing decorative effects by removing surface material, e.g. by engraving, by etching, B44C1/22; electrolytic etching or polishing C25F); INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
- B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02)
- C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D)
- C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09)

## Abstract

Disclosed are methods of treating a metal to improve the metal's corrosion resistance. The method includes applying, to the surface of the metal, a coating which comprises magnesium powder and a binder. The present invention also relates to a coating composition that includes magnesium powder and a silane modified epoxy isocyanate hybrid polymer or prepolymer. The inventors have found that corrosion resistance (as determined by Prohesion™ exposure in accordance with ASTM D5894-96, which is hereby incorporated by reference) in excess of 3,000 hours on 2024 T-3 aluminum alloy can be achieved with the methods and coating compositions of the present invention.

## Claims

### Claim 1

A coating composition comprising: magnesium powder; and a silane modified epoxy isocyanate hybrid polymer or prepolymer.

### Claim 2 (depends on 1)

A coating composition according to claim 1, wherein said magnesium powder is substantially uniformly dispersed in said silane modified epoxy isocyanate hybrid polymer or prepolymer.

### Claim 3 (depends on 1)

A coating composition according to claim 1, wherein said magnesium powder comprises a mixture of a first magnesium particle powder and a second magnesium particle powder, wherein the first magnesium particle powder and a second magnesium particle powder have substantially different mean particle size distributions, wherein the mixture's bulk density, and wherein the mixture's bulk density is greater than that of the second magnesium particle powder's bulk density.

### Claim 4 (depends on 3)

A coating composition according to claim 3, wherein the first magnesium particle powder has a mean particle size distribution of from about 25 mm to about 35 mm and wherein the second magnesium particle powder has a mean particle size distribution of from about 65 mm to about 75 mm.

### Claim 5 (depends on 4)

A coating composition according to claim 4, wherein the first magnesium particle powder has a mean particle size distribution of about 30 mm and wherein the second magnesium particle powder has a mean particle size distribution of from about 70 mm.

### Claim 6 (depends on 4)

A coating composition according to claim 4, wherein the mixture contains first magnesium particle powder and second magnesium particle powder in a volume ratio of from about 40:60 to about 60:40.

### Claim 7 (depends on 4)

A coating composition according to claim 4, wherein the mixture contains first magnesium particle powder and second magnesium particle powder in a volume ratio of from about 45:55 to about 55:45.

### Claim 8 (depends on 4)

a coating composition according to claim 4, wherein the mixture contains first magnesium particle powder and second magnesium particle powder in a volume ratio of from about 50:50 to about 55:45.

### Claim 9 (depends on 8)

A coating composition according to claim 8, wherein the first magnesium particle powder has a mean particle size distribution of about 30 mm and wherein the second magnesium particle powder has a mean particle size distribution of from about 70 mm.

### Claim 10 (depends on 9)

A coating composition according to claim 9, wherein the mixture contains first magnesium particle powder and second magnesium particle powder in a volume ratio of about 58:42.

### Claim 11 (depends on 1)

A coating composition according to claim 1, wherein said silane modified epoxy isocyanate hybrid polymer or prepolymer comprises a polyisocyanate prepolymer, an epoxy prepolymer, and a silanated tetrahydroquinoxalinol crosslinker or a polymerization product thereof.

### Claim 12 (depends on 11)

A coating composition according to claim 11, wherein the polyisocyanate prepolymer is an aliphatic polyisocyanate prepolymer.

### Claim 13 (depends on 11)

A coating composition according to claim 11, wherein the polyisocyanate prepolymer is an aromatic polyisocyanate prepolymer.

### Claim 14 (depends on 11)

A coating composition according to claim 11, wherein the silanated tetrahydroquinoxalinol crosslinker is a 7-phenyl-1-[4-(trialkylsilyl)-alkyl]-1,2,3,4-tetrahydroquinoxalin-6-ol.

### Claim 15 (depends on 11)

A coating composition according to claim 11, wherein the silanated tetrahydroquinoxalinol crosslinker is a 7-phenyl-1-[4-(trialkylsilyl)-butyl]-1,2,3,4-tetrahydroquinoxalin-6-ol.