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(12) United States Patent (10) Patent No.: US 6,887,320 B2 Briles Et Al

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(12) United States Patent (10) Patent No.: US 6,887,320 B2 Briles Et Al USOO6887320B2 (12) United States Patent (10) Patent No.: US 6,887,320 B2 Briles et al. (45) Date of Patent: May 3, 2005 (54) CORROSION RESISTANT, CHROMATE- 5,683,522. A 11/1997 Joesten FREE CONVERSION COATING FOR MAGNESIUM ALLOYS FOREIGN PATENT DOCUMENTS (75) Inventors: Owen M. Briles, Rockford, IL (US); JP 2001 123274 A * 5/2001 ........... C23C/22/18 Mark Jaworowski, Glastonbury, CT (US); Michael A. Kryzman, West * cited by examiner Hartford, CT (US) (73) Assignees: United Technologies Corporation, Primary Examiner Roy King Hartford, CT (US); Hamilton ASSistant Examiner-Lois Zhang Sundstrand Corporation, Windsor (74) Attorney, Agent, or Firm-Bachman & LaPointe, P.C. Locks, CT (US) (57) ABSTRACT (*) Notice: Subject to any disclaimer, the term of this The present invention relates to a process for forming a patent is extended or adjusted under 35 chromate-free, corrosion resistant coating on a product U.S.C. 154(b) by 373 days. formed from magnesium or a magnesium alloy and to a Solution used for forming the coating. The Solution has (21) Appl. No.: 10/073,688 phosphate and fluoride ions and contains from 1.0 g/l to 5.0 (22) Filed: Feb. 11, 2002 g/l of an active corrosion inhibitor Selected from the group 9 consisting potassium permanganate, Sodium tungstate, (65) Prior Publication Data Sodium Vanadate, and mixtures thereof. The Solution may US 2003/O150525A1 Aug. 14, 2003 also containing from 0.1 to 1.0 vol% of a surfactant which f lug. 14, reduces reaction time. The Solution is maintained at a (51) Int. Cl. ................................................ C23C 22/07 temperature of 120 to 200 degrees Fahrenheit and has a pH (52) U.S. Cl. ....................... 148/253; 148/261; 148/275; of 5 to 7. The process for forming the coating broadly 106/14.12; 252/389.54 comprises degreasing the magnesium or magnesium alloy (58) Field of Search ................................. 148,243, 253, product in a degreasing Solution, cleaning the product in a 148/261, 275; 106/14.12; 252/389.54 highly alkaline cleaning Solution, deoxidizing the product in a deoxidizing Solution, and immersing the product in the (56) References Cited coating solution for a time period of 15 minutes to 90 minutes. U.S. PATENT DOCUMENTS 5,520,750 A * 5/1996 Riley ......................... 148/261 20 Claims, 1 Drawing Sheet DEGREASING MAGNESUM O ALOY PRODUCT CLEANING MAGNESUM ALOY PRODUCT DEOXDZNG MAGNESUM ALOY PRODUC MMERSING MAGNESIUM 16 ALLOY PRODUCT U.S. Patent May 3, 2005 US 6,887,320 B2 DEGREASING MAGNESUM ALLOY PRODUCT CLEANING MAGNESIUM ALLOY PRODUCT DEOXDZNG MAGNESUM ALLOY PRODUCT MMERSING MAGNESUM ALLOY PRODUCT US 6,887,320 B2 1 2 CORROSION RESISTANT, CHROMATE Same, as well as objects and advantages attendant thereto, FREE CONVERSION COATING FOR are set forth in the following detailed description and the MAGNESIUM ALLOYS accompanying drawing wherein like reference numerals depict like elements. BACKGROUND OF THE INVENTION BRIEF DESCRIPTION OF THE DRAWING The present invention relates to a process for applying a The FIGURE is a process flow diagram of an embodiment corrosion resistant, chromate-free conversion coating to a of the instant invention illustrating a non-electrolytic proceSS product formed from magnesium or a magnesium alloy and for applying a chromate free, corrosion resistant conversion to a coating Solution used in the process. coating to a product formed from magnesium or a magne Magnesium alloys are light and Strong, but very Vulner sium alloy. able to corrosion due to the reactive nature of magnesium. Magnesium alloys are protected from corrosion in all prac DETAILED DESCRIPTION OF THE tical applications. A commonly used, low cost, corrosion PREFERRED EMBODIMENT(S) resistant treatment for magnesium alloys is a dichromate 15 The FIGURE illustrates a process flow diagram for a based conversion coating. While dichromate based conver non-electrolytic proceSS for applying a chromate-free, cor Sion coatings provide good corrosion protection, they are rosion resistant coating to a product formed from magne based on a chemical compound (hexavalent chromium) that sium or a magnesium alloy. In the aircraft industry, for has many occupational exposure risks. A non-chromated, example, the magnesium alloy product may include any corrosion resistant magnesium conversion coating is number of operational components Such as a generator required to meet industry demands. housings or gearbox components. Another treatment for protecting magnesium or magne The non-electrolytic proceSS may begin with an initial sium alloy products is shown in U.S. Pat. No. 5,683,522 to Step 10 of degreasing the magnesium alloy product in a Joesten, which is hereby incorporated by reference herein. In 25 degreasing Solution. An aqueous-based Solution, Such as that this treatment, a paint adherent and corrosion resistant commonly known and Sold in the industry under the trade coating of magnesium phosphate and magnesium fluoride is mark OAKITE SC 225, may be used to serve the function applied to a product formed from a magnesium alloy. The of degreasing the magnesium product. This initial Step 10 proceSS for applying the coating involves immersing the allows for removal of oils and other contaminants on the magnesium alloy product in a Solution having phosphate and Surface of the magnesium which can Subsequently prevent fluoride ions. This treatment while providing a barrier film wetting of the Surface of a housing, and inhibit the chemical and very good paint adhesion, does not include electro reaction if not removed. One skilled in the art can appreciate chemically active ingredients to Suppress corrosion. that other organic Solvents, Such as that known in the SUMMARY OF THE INVENTION industry and sold under the label, Blue Gold Industrial 35 Cleaner which is manufactured by Carroll Company, or Accordingly, it is an object of the present invention to halogenated Solvents Such as N-propyl bromide may also provide a process for forming an improved chromate-free Serve the degreasing function. corrosion resistant conversion coating for magnesium and In addition to the degreasing Step 10, the non-electrolytic magnesium alloy products. process may include cleaning the magnesium alloy product It is a further object of the present invention to provide a 40 in a highly alkaline aqueous-based cleaning Solution in a coating Solution for forming the chromate-free corrosion cleaning Step 12. An example of a highly alkaline cleaner resistant coating. which may be utilized in the cleaning Step 12 is known and The foregoing objects are attained by the present inven sold in the industry under the trademark TURCO ALKA tion. LINE RUST REMOVER, and manufactured by Turco In accordance with the present invention, a process for 45 Products, Inc. Preferably, during the cleaning Step 12, the applying a chromate free, corrosion resistant conversion alkaline bath of cleaning Solution is continuously agitated coating to a product formed from magnesium or a magne while in use, and maintained at a temperature in a range of sium alloy broadly comprises the Steps of degreasing the approximately 180-200 degrees Fahrenheit. In addition, in product in an aqueous degreasing Solution, cleaning the order to achieve an optimum cleaning effect, the concentra product in a highly alkaline cleaning Solution, deoxidizing 50 tion of the cleaning Solution may be provided at approxi the product in a deoxidizing Solution, and immersing the mately 20–30 ounces of highly alkaline cleaner per gallon of product in a Solution containing phosphate and fluoride ions cleaning Solution, with the cleaning Solution having a pH of where a pH level of the Solution is controlled in an approxi at least 11. By controlling the variables of concentration and mate range of 5 to 7, the solution being provided with 1.0 g/l pH of the cleaning Solution, a preferable cleaning effect may to 5.0 g/l of an active corrosion inhibitor and being main 55 be achieved while immersing the magnesium alloy product tained at a temperature of approximately 120 to 200 degrees in the cleaning Solution for a period of approximately 3–5 Fahrenheit while immersing the product for a time period in minutes. The cleaning Step 12 further removes impurities the range of 15 to 90 minutes. from the Surface of the magnesium alloy product which The Solution used to form the chromate-free, corrosion could inhibit the chemical reaction necessary to form the resistant coating on a magnesium or magnesium alloy prod 60 conversion coating of the instant invention. uct comprises the Solution having phosphate and fluoride The non-electrolytic process of the instant invention may ions, and containing from 1.0 g/l to 5.0 g/l of an active further include a deoxidizing Step 14 which includes deoxi corrosion inhibitor. AS mentioned above, the Solution has a dizing the magnesium alloy product in a deoxidizing Solu pH of 5 to 7. The solution may contain 0.01 to 1.0 vol% of tion. One solution for effectively deoxidizing may be for a Surfactant which reduces the reaction time. 65 mulated from Sodium acid fluoride, with a concentration of Other details of the magnesium alloy conversion coating the deoxidizing Solution being provided at approximately of the present invention and of the process for applying 3.5-7.0 ounces of sodium acid fluoride per gallon of deoxi US 6,887,320 B2 3 4 dizing Solution, and a temperature of the Solution being fluoride ions is measured in terms of a concentration by maintained at approximately 70-90 degrees Fahrenheit. weight of sodium bifluoride (NaHF). In a preferred Preferably, the deoxidizing Solution is not agitated while embodiment, the concentration is provided at about deoxidizing the magnesium alloy product for an optimum 0.3-0.5% by weight sodium bifluoride; this range of con period of time of approximately 3-5 minutes.
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