United States Patent (19) 11 Patent Number: 4,889,558 Mosser 45 Date of Patent: Dec

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United States Patent (19) 11 Patent Number: 4,889,558 Mosser 45 Date of Patent: Dec United States Patent (19) 11 Patent Number: 4,889,558 Mosser 45 Date of Patent: Dec. 26, 1989 54 COATING COMPOSITIONS CONTAINING 56) References Cited UN DISSOLVED HEXAVALENT U.S. PATENT DOCUMENTS CHROMUMSALT 2,902,390 9/1959 Bell ... ... 148/6.2 (75) Inventor: Mark F. Mosser, Sellersville, Pa. 3,049,441 6/1963 Curtin ... ... 148/6.16 3,248,249 4/1966 Collins ................................ 106/286 73) Assignee: Sermatech International, Inc., 3,248,251 4/1966 Allen ............. ... 106/286.2 Limerick, Pa. 3,869,293 3/1975 Brumbaugh ........................... O6/14 (21) Appl. No.: 777,228 Primary Examiner-A. Lionel Clingman 22 Filed: Sep. 18, 1985 Assistant Examiner-John F. McNally Attorney, Agent, or Firm-Weiser & Stapler Related U.S. Application Data 57 ABSTRACT 63) Continuation-in-part of Ser. No. 555,477, Nov. 28, A coating composition for providing a part with im 1983, abandoned. proved salt spray resistance, which comprises undis (51) Int. Cl." ................................................ C04B 9/02 solved solid hexavalent chromate in an aqueous acid 52) U.S. Cl. ................................... 106/14.12; 75/234; solution which is the reaction product of phosphate ions 106/1.12; 106/1.22; 106/14.21; 106/286.5; with ions of the group consisting of chromate or molyb 428/457 date ions, and their coatings and coated parts. (58) Field of Search .......................... 106/14.12, 14.21; 148/6.16, 1.12, 1.16, 1.17 18 Claims, No Drawings 4,889,558 1. 2 lent chromium salts which comes about from the com COATING COMPOSITIONS CONTAINING plete reduction of all of the hexavalent chromium salts UNDSSOLVED HEXAVALENT CHROMUM to trivalent chromium salts (hereafter all chromium salts SALT shall be referred to as trivalent or hexavalent chro 5 mium). The ultimate objective of Bernath is an adherent This Application is a continuation-in-part application conversion coating on a metal substrate which is an of application Ser. No. 555,477 filed Nov. 28, 1983, now organic resin coating. Bernath's work is based primarily abandoned. on the fact that the reactants include a solvent with a The present invention relates to coating compositions variety of synthetic resins such as epoxies, alkyds, or for coating metal parts so as to improve their corrosion 10 ganosols etc, all reactants being in a predetermined resistance to atmospheric and other environmental con ratio. No more chemicals are added than are necessary ditions to which they are exposed. The invention fur for the completion of the reaction and the formation of ther relates to coating compositions which will form a the conversion coating. The conversion coating by primer coating so as to improve the adhesion between a definition is bonded during the bake period by causing a metal part and a top coating. 15 chemical conversion bond between the substrate and The invention also relates to the metal parts coated the coating as disclosed by Bernath. This occurs in with such compositions and to a method for coating Bernath's coating by the trivalent chromium which had metal parts. More particularly, the invention relates to been produced at an earlier stage. The coating is oxi aqueous coating compositions containing a dissolved dized by heat (or other means) to produce hexavalent chromium compound or phosphate and chromium or 20 chromium to which the bonding to the metal base is molybdenum compound and particles of leachable attributable. chromate pigments. It is essential for Bernath's coating composition that Coating compositions are known which consists es the organic liquid coating composition which contains sentially of a slurry of solid inorganic particulate mate resin, also contain hexavalent chromate on dichromate rial in an aqueous acidic solution containing substantial 25 amounts of dissolved metal, chromate, dichromate, or and sufficient oxidizable material to reduce completely molybdate and phosphate. After application of such the hexavalent chromium to trivalent chromium com coating to a substrate, it is heated to a temperature of pounds. This is a fundamental distinction over the prior about 500 F. until the coating is water insoluble. Such art which Bernath points out. That is, in the prior art, a coatings usually incorporate therein metal powders, 30 specified proportion of hexavalent chromium must al such as aluminum powder, as the solid particulate mate ways remain if satisfactory results were to be obtained. rial so as to provide a sacrificial corrosive protection. Bernath states that for reasons which he has not yet That is, where, for example, the substrate for the coat found adequate explanation, the hexavalent chromium ing is ferrous metal, the aluminum powder in the coat ion which is initially present, must be reduced by an ing, by way of electrode chemical reactions which 35 oxidizable component in the liquid coating mixture, to ensue in a salt-spray or other corrosive atmosphere, the trivalent state. After reaction of the hexavalent generally sacrifices itself to the end that there is little or chromium with the oxidizable component to trivalent no corrosion of the ferrous metal substrate. It has fur chromium, the resulting liquid organic mixture which ther been established, that this property of the sacrifi contains also inorganic components, is identifiable by ciality of the coating in providing the increased corro the total absence of detectable hexavalent chromium. sion protection is greatly enhanced by so processing the In accordance with Bernath's teaching, the liquid coating as to render it electrically conductive. Usually, coating composition is also constituted by an organic the aluminum filled coatings are made sacrificial and primer composition which may contain the organic galvanically active by either cold working (burnishing) resins, such as the epoxy resins or a solvent, such as an the coating surface, or by heat treating to a temperature 45 alcohol. of about 1000' F. for ninety minutes. Other heat treat The absence of hexavalent chromium as a result of ments can be used. The goal being to produce an electri the reduction to trivalent chromium is readily identifia cally conductive aluminum coating that is sacrificial, i.e. ble by the change of color from the yellow-orange color will corrode and protect the adjacent base metal areas of the hexavalent chromium to the green color charac from corrosion. 50 teristic of trivalent chromium. This is evident from the Sacrificial, burnished or heat treated coatings of this examples of Bernath. The reduction reaction is exother type are commonly used on jet engine compressor hard C. ware. In other applications burnished or heat treated It is critical that the components of Bernath's liquid coatings may be used in salt environments and/or in composition include an oxidizable component in suffi elevated temperatures. In salt environments, particu 55 cient amounts to reduce all of the Cr-6 to Cr-3 so that larly when coupled with elevated temperatures, the the final liquid mixture is characterized by the total galvanic activity of the coatings produce white corro absence of chromium in the -- 6 state, all of the chro sion products or gelatinous masses of aluminum hydrox mium being in the +3 state. In accordance with Ber ide and other products. In many applications, these nath, the oxidizable component may be in one of two white products or "white rust' are as undesirable as 60 forms; either it is an integral part of the reactive resin, or normal rust. it may be added in the form of a organic compound or Other techniques and compositions have been pro reagent which is capable of reducing the chromium to posed in addition to what has been discussed above for the +3 state. Bernath illustrates the type of resins which producing corrosion resistant and protective coatings are capable of the reduction of the hexavalent chro on metal substrates. U.S. Pat. No. 3,713,904 to Bernath 65 mium to trivalent chromium. He also illustrates the type et al discloses a coating composition containing an or of organic solvents (primarily alcohols and aldehydes) ganic resin. Bernath points out that the novelty of his such as Carbitol, Isophorone and other oxidizable sol organic resinous coating is that it always contains triva vents which are reactive enough to reduce the hexava 4,889,558 3 4. lent chromium to trivalent chromium; after the reduc the invention are set forth for the purpose of contrasting tion a gel is produced. and distinguishing over the above described prior art. In It is an objective of Bernath to fully first reduce the the present invention, the liquid coating composition is hexavalent chromium to trivalent chromium. This is virtually and essentially exclusively aqueous. It is not an illustrated by his attempts to accomplish the same re organic solution although the aqueous solution may sults by adding trivalent chromate directly to the mix contain optionally some resins in dispersion. The coat ture without the necessity of first reducing the hexava ing is primarily an inorganic coating, i.e. the essential lent chromate to the trivalent state, which results he components are inorganic. reports were quite unsatisfactory in every case. Of primary importance is that the aqueous solution Thus the Bernath liquid composition before applica- 10 contains two types of chromates, a first chromate which tion to the substrate and baking is characterized in that is an essential constituent of what is called the binder the hexavalent chronium is in solution completely and component of the aqueous composition and a second reduced to trivalent chromium. The medium is primar chromate which is not so reacted, and which is further ily an organic medium either because of the resin or the described herein. The first chromate dissolves along organic solvent. The change in color as a result of the 15 with the phosphate ions of the binder.
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