# US 2021/0172069 A1 · Coating for steel, coated steel and a method of the same

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- Number: US 2021/0172069 A1
- Document ID: US20210172069A1
- Status: Published application
- Kind: A1
- Application number: 16/614,038
- Filed: 2018-05-16
- Published: 2021-06-10
- Earliest claimed: 2017-05-18
- Applicants: Magna International Inc.
- Inventors: Jeremiah John BRADY; Edward Karl STEINEBACH; Richard Lee WINFREE; Vinod Kumar SIKKA; Kenneth Ray ADAMS
- Web page: https://patentgrep.com/patent/US20210172069A1

## CPC

- C23C 10/02: Pretreatment of the material to be coated (C23C10/04 takes precedence)
- B32B 15/01: all layers being exclusively metallic {(making layered metal workpieces by pressure cladding B23K20/22; making coatings with a metallic material characterised by its composition C23C30/00)}
- B32B 15/012: {one layer being formed of an iron alloy or steel, another layer being formed of aluminium or an aluminium alloy}
- B32B 15/013: {one layer being formed of an iron alloy or steel, another layer being formed of a metal other than iron or aluminium}
- B32B 15/017: {one layer being formed of aluminium or an aluminium alloy, another layer being formed of an alloy based on a non ferrous metal other than aluminium}
- B32B 15/20: comprising aluminium or copper {(B32B15/016 and B32B15/017 take precedence)}
- C22C 18/04: with aluminium as the next major constituent
- C22C 19/007: {with a light metal (alkali metal Li, Na, K, Rb, Cs; earth alkali metal Be, Mg, Ca, Sr, Ba, Al Ga, Ge, Ti) or B, Si, Zr, Hf, Sc, Y, lanthanides, actinides, as the next major constituent}
- C22C 19/03: based on nickel
- C22C 21/02: with silicon as the next major constituent
- C22C 38/04: containing manganese
- C23C 4/04: characterised by the coating material
- C23C 10/18: using liquids, e.g. salt baths, liquid suspensions
- C23C 10/30: using a layer of powder or paste on the surface (using liquid suspensions of solids C23C10/18)
- C23C 10/32: Chromising
- C23C 10/50: of ferrous surfaces
- C23C 10/58: more than one element being diffused in more than one step
- C23C 22/02: using non-aqueous solutions
- C23C 24/08: by application of heat or pressure and heat (C23C24/04 takes precedence)
- C23C 24/087: {Coating with metal alloys or metal elements only}
- C23C 28/02: only coatings {only including layers} of metallic material
- C23C 28/021: {including at least one metal alloy layer}
- B22F 1/05: Metallic powder characterised by the size or surface area of the particles
- B22F 2007/047: {non-pressurised baking of the paste or slurry containing metal powder}
- B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy
- Y10T 428/12028: Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, etc.]
- C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C22C: ALLOYS (treatment of alloys C21D, C22F)
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A coating process employing coating techniques which allow an end-user to coat steel, rather than relying on a specialized location or supplier, is provided. The techniques produce a coating having high temperature oxidation resistance, greater corrosion resistance, and added surface lubricity to minimize die wear during a stamping process. The techniques also allow configurability with surface textures and allow thickness control. In addition, selective coating of a part or product, for example, around a weld area, and the addition of componentry, for example sensors, with the sensors being employed to monitor the coating, is possible. The coating includes a top functional layer including least one of Al, Ni, Fe, Si, B, Mg, Zn, Cr, h-BN, and Mo, and an interfacial layer with intermetallics formed therein. The interfacial layer can consist of at least one intermetallic, or the interfacial layer can include a mixture of the intermetallic(s) and steel.

## Claims

### Claim 1

A component, comprising:
a substrate formed of steel or steel-based material,
an interfacial layer disposed on said substrate, said interfacial layer including aluminum,
said interfacial layer including at least one intermetallic, and
a top functional layer disposed on said interfacial layer, said top functional layer including at least one of Al, Ni, Fe, Si, B, Mg, Zn, Cr, h-BN, and Mo.

### Claim 2 (depends on 1)

The component of claim 1, wherein said at least one intermetallic is selected from the group consisting of: Fe3Al, FeAl, Fe2Al5, and FeAl2.

### Claim 3 (depends on 1)

The component of claim 1, wherein said top functional layer includes Ni, and said at least one intermetallic is selected from the group consisting of NiAl, Ni3Al, Ni2Al3, and NiAl3.

### Claim 4 (depends on 1)

The component of claim 1, wherein said interfacial layer further includes at least one of Si in an amount of 0.5 to 15 wt %, B in an amount of 0.5 to 15 wt %, Mg in an amount of 0.5 to 85 wt %, Zn in an amount of 0.5 to 85 wt %, and Ni in an amount of 0.5 to 85 wt %, based on the total weight of said interfacial layer.

### Claim 5 (depends on 1)

The component of claim 1, wherein said interfacial layer is formed by a first slurry which includes at least one of a binder, suspending agent, dispersant, surfactant, and flux agent; and said top functional layer is formed by a second slurry which includes at least one of a binder, suspending agent, dispersant, surfactant, and flux agent.

### Claim 6

A method of manufacturing a component, comprising the steps of:
applying an interfacial layer to a substrate formed of steel or steel-based material, the interfacial layer being applied as a first slurry containing aluminum in the form of powder,
heating the interfacial layer to a temperature ranging from about 100 to about 600° C. after applying the interfacial layer to the steel substrate,
heating the interfacial layer to a temperature ranging from 600 to 954° C. after heating the interfacial layer to a temperature ranging from about 100 to about 600° C.
applying a top functional layer to the interfacial layer, the top functional layer being applied as a second slurry containing at least one of Al, Ni, Fe, Si, B, Mg, Zn, Cr, h-BN, and Mo in the form of powder,
heating the top functional layer to a temperature ranging from about 100 to about 600° C. after applying the top functional layer to the interfacial layer, and
heating the top functional layer to a temperature ranging from 600 to 954° C. after heating the top functional layer to a temperature ranging from about 100 to about 600° C.

### Claim 7 (depends on 6)

The method of claim 6, wherein the step of heating the interfacial layer to a temperature ranging from 600 to 954° C. forms at least one intermetallic in the interfacial layer.

### Claim 8 (depends on 7)

The method of claim 7, wherein the at least one intermetallic is selected from the group consisting of: Fe3Al, FeAl, Fe2Al5, FeAl2, NiAl, Ni3Al, Ni2Al3, and NiAl3.

### Claim 9 (depends on 6)

The method of claim 6, wherein the powders in the interfacial layer and the top functional layer have a particle size of not greater than 100 microns.

### Claim 10 (depends on 6)

The method of claim 6, wherein the steps of applying the layers each include at least one of: dipping, brushing, atmosphere plasma spray, vacuum plasma spraying, high velocity spraying (HVOF), flame spraying, wire arc spraying, core wire arc spraying, physical vapor deposition (PVD), and chemical vapor deposition (CVD).

### Claim 11 (depends on 6)

The method of claim 6, wherein the first slurry further includes at least one component selected from the group consisting of: a binder, suspending agent, dispersant, solvent, surfactant, and flux agent; and the second slurry further includes at least one component selected from the group consisting of: a binder, suspending agent, dispersant, solvent, surfactant, and flux agent.

### Claim 12 (depends on 6)

The method of claim 6 including etching or abrading the substrate to remove oxides from the substrate before applying the interfacial layer to the substrate.

### Claim 13 (depends on 12)

The method of claim 12 including removing any grease or oil from the substrate before etching or abrading the substrate, wherein the step of removing any oil or grease from the substrate includes applying a solution including a solvent, alkali, and a surfactant to the substrate, the solvent including at least one of acetone, alcohol, and MEK, the alkali including at least one of NaOH and KOH in an amount of 1 to 5 wt %, based on the total weight of the solution, the solution being at a temperature of 125 to 150° F. when applied to the substrate, and further including the step of removing the solution from the substrate by applying water at a temperature of 125 to 175° F. to the substrate and removing water from the substrate before applying the interfacial layer.

### Claim 14 (depends on 6)

The method of claim 6 further including quenching the substrate after the heating steps, and forming the substrate after the quenching step, the forming step including hot or cold stamping.

### Claim 15 (depends on 7)

The method of claim 7, wherein the top functional layer includes Ni, and the at least one intermetallic is selected from the group consisting of NiAl, Ni3Al, Ni2Al3, and NiAl3.

### Claim 16 (depends on 1)

The component of claim 1, wherein said interfacial layer includes Zn and Si.

### Claim 17 (depends on 1)

The component of claim 1, wherein a total amount of intermetallics present in said coating, including said at least one intermetallic of said interfacial layer, ranges from 2 wt % to 7 wt %, based on the total weight of said coating.

### Claim 18 (depends on 4)

The component of claim 4, wherein said interfacial layer includes the B in an amount of 0.5 to 15 wt %, based on the total weight of said interfacial layer.

### Claim 19 (depends on 11)

The method of claim 11, wherein all powder formed of metal present in the first slurry, including the aluminum powder, has a particle size ranging from 2 to 7 microns.

### Claim 20 (depends on 11)

The method of claim 11, wherein the first slurry includes the binder in an amount of 5 wt % to 15 wt %, based on the total weight of the first slurry.