# US 8,541,349 B2 · Lubricant-hard-ductile nanocomposite coatings and methods of making

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- Number: US 8,541,349 B2
- Document ID: US8541349B2
- Status: Granted
- Kind: B2
- Application number: 11/858,750
- Filed: 2007-09-20
- Published: 2009-06-18
- Granted: 2013-09-24
- Earliest claimed: 2006-09-21
- Assignees: Inframat Corporation
- Applicants: T. Danny Xiao; John Broadhead; Xinqing Ma
- Inventors: T. Danny Xiao; John Broadhead; Xinqing Ma
- Web page: https://patentgrep.com/patent/US8541349B2

## CPC

- C25D 15/02: Combined electrolytic and electrophoretic processes {with charged materials}
- C23C 4/06: Metallic material
- C23C 4/10: Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
- C23C 4/129: Flame spraying
- C23C 30/00: Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process (C23C26/00, C23C28/00 take precedence)
- Y02T 50/60: Efficient propulsion technologies, e.g. for aircraft
- C25D: PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- 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)
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

Lubricant-hard-ductile composite coating compositions and methods of making the same are provided. In embodiment, a composite coating composition comprises: a lubricant phase for providing lubrication to a surface; a hard ceramic phase for providing structural integrity and wear resistance to the surface; and a ductile metal phase for providing ductility to the surface.

## Claims

### Claim 1

A composite coating composition comprising:
a ductile metal phase for providing ductility to a surface, wherein the ductile metal phase comprises a compound selected from the group consisting of a transition metal, Co, Ni, Fe, Mo, Cr, Cu, W, Ta, In, Tl, an alloy of metals or transition metals, or a combination comprising at least one of the foregoing;
a lubricant phase comprising particles having a dimension of less than 100 nanometers (“nanoparticles”) distributed in the ductile metal phase for providing lubrication to the surface; and
a hard ceramic phase comprising particles having a dimension of less than 100 nanometers distributed in the ductile metal phase for providing structural integrity and wear resistance to the surface, wherein said coating has a Vickers Hardness Number of 400-1000.

### Claim 2 (depends on 1)

The composite coating composition of claim 1, wherein the hard ceramic phase comprises nanoparticles at least partially coated with the lubricant phase and distributed in the ductile metal phase.

### Claim 3 (depends on 1)

The composite coating composition of claim 1, wherein the lubricant phase comprises a compound selected from the group consisting of BN, Fe1-xS where x is about 0.01 to about 0.5, MoS2, WS2, TiS2, NbS2, TiSe2, NbSe2, MoSe2, TaS2, TaSe2, graphite, CaF2, Fe3O4, a fluoropolymer, or a combination comprising at least one of the foregoing.

### Claim 4 (depends on 1)

The composite coating composition of claim 1, wherein the hard ceramic phase comprises a compound selected from the group consisting of Al2O3, Cr2O3, ZrO2, CeO2, WC, TiC, VC, Cr3C2, TaC, SiC, aluminum nitride, silicon nitride, zirconium nitride, TiB2, zirconium boride, diamond nanoparticles, or a combination comprising at least one of the foregoing.

### Claim 5 (depends on 1)

The composite coating composition of claim 1, wherein the composite coating is a nanostructured coating comprising a BN phase, a Cr2O3 phase, and a Ni phase.

### Claim 6 (depends on 1)

The composite coating composition of claim 1, wherein the composite coating is a nanostructured coating comprising a Fe3O4 phase, a Cr2O3 phase, and a Ni phase.

### Claim 7 (depends on 1)

The composite coating composition of claim 1, wherein the composite coating is a nanostructured coating comprising a BN phase, a WC phase, and a Co phase.

### Claim 8 (depends on 1)

The composite coating composition of claim 1, wherein the composite coating is a nanostructured coating comprising a BN phase, a Cr2O3 phase, and a NiCr phase.

### Claim 9 (depends on 1)

The composite coating composition of claim 1, wherein the composite coating is a nanostructured coating comprising a BN phase, a SiC phase, and a Ni or NiCr phase.