Methods of coating substrates with composite coatings of diamond nanoparticles and metal

• US 10,669,635 B2
• Filed: 09/18/2014
• Issued: 06/02/2020
• Est. Priority Date: 09/18/2014
• Status: Active Grant

• Current Assignee: Baker Hughes Holdings LLC (Baker Hughes Company)
• Original Assignee: Baker Hughes, a GE Company, LLC (Baker Hughes Company)
• Inventors: Monteiro, Othon R., Mazyar, Oleg A., Khabashesku, Valery N.
• Primary Examiner(s): Bareford, Katherine A
• Assistant Examiner(s): McClure, Christina D
• Application Number:
  US14/490,214
• Publication Number:
  US 20160083860A1
• Time in Patent Office: 2,084 Days
• CPC Class Codes: C23C 18/1646 Characteristics of the product obtained
• CPC Class Codes: C23C 18/1662 Use of incorporated material in the solution or dispersion, e.g. particles, whiskers, wires
• CPC Class Codes: C25D 15/00 Electrolytic or electrophoretic production of coatings containing embedded materials, e.g. particles, whiskers, wires
• CPC Class Codes: C25D 3/665 from ionic liquids

Abstract

A method of coating a substrate includes dispersing functionalized diamond nanoparticles in a fluid comprising metal ions to form a deposition composition; disposing a portion of the deposition composition over at least a portion of a substrate; and electrochemically depositing a coating over the substrate. The coating comprises the diamond nanoparticles and a metal formed by reduction of the metal ions in the deposition composition.

Claims

1. A method of coating a substrate by electrodeposition, comprising:

dispersing functionalized diamond nanoparticles in an ionic liquid comprising cations and anions to form a deposition composition comprising the functionalized diamond nanoparticles dispersed within the ionic liquid, wherein the cations comprise metal ions, wherein the functionalized diamond nanoparticles comprise at least one functional group selected from the group consisting of carboxy, epoxy, ether, ketone, amine, hydroxy, alkoxy, alkyl, aryl, aralkyl, alkaryl, lactone, polymeric groups, oligomeric groups, quaternary ammonium groups, quaternary phosphonium groups, tertiary sulfonium groups, alkyl pyridinium groups, primary amines, secondary amines, tertiary amines, aminoethyl, dimethylaminoethyl, diethylaminoethyl, guanidinium, and imidazolium, the ionic liquid comprising a polymerizable group that provides a net positive charge to the functionalized diamond nanoparticles through covalent modification of the functionalized diamond nanoparticles with the ionic liquid or by polymerization of the ionic liquid on a surface of the functionalized diamond nanoparticles;

disposing a portion of the deposition composition over at least a portion of a substrate; and

electrochemically depositing a coating over the substrate, the coating comprising the diamond nanoparticles and a metal formed by reduction of the metal ions in the deposition composition.

2. The method of claim 1, wherein electrochemically depositing a coating over the substrate comprises forming a coating having a thickness of at least about 10 μ

m.

3. The method of claim 2, wherein electrochemically depositing a coating over the substrate comprises forming a coating having a thickness in a range from about 50 μ

m to about 100 μ

m.

4. The method of claim 1, wherein electrochemically depositing a coating over the substrate comprises continuously forming the coating over the surface of the substrate.

5. The method of claim 1, wherein dispersing functionalized diamond nanoparticles in an ionic liquid comprising cations and anions comprises dispersing functionalized diamond nanoparticles having a particle size in a range from about 20 nm to about 1 μ

m.

6. The method of claim 1, wherein electrochemically depositing a coating over the substrate comprises electroless deposition of the metal onto a surface of the substrate.

7. The method of claim 1, wherein electrochemically depositing a coating over the substrate comprises electroplating the coating over the substrate, further comprising disposing an anode within deposition composition, the anode having a size and shape corresponding to a size and shape of the substrate.

8. The method of claim 1, wherein disposing a portion of the deposition composition over at least a portion of a substrate comprises disposing a portion of the deposition composition over at least a portion of a substrate comprising an electrically conductive material.

9. The method of claim 8, wherein disposing a portion of the deposition composition over at least a portion of a substrate comprising an electrically conductive material comprises disposing a portion of the deposition composition over at least a portion of a substrate comprising at least one material selected from the group consisting of aluminum, bismuth, boron, calcium, cobalt, copper, chromium, iron, lead, magnesium, manganese, molybdenum, nickel, niobium, nitrogen, phosphorous, selenium, sulfur, tantalum, tellurium, titanium, tungsten, vanadium, zirconium, silicon, zinc, a rare earth element, and combinations and alloys thereof.

10. The method of claim 1, wherein disposing a portion of the deposition composition over at least a portion of a substrate comprises disposing a portion of the deposition composition over at least a portion of a substrate comprising an electrically nonconductive material.

11. The method of claim 1, wherein dispersing functionalized diamond nanoparticles in an ionic liquid comprises dispersing functionalized diamond nanoparticles in a polymerizable ionic liquid and a non-polymerizable ionic liquid.

12. The method of claim 1, wherein dispersing functionalized diamond nanoparticles in an ionic liquid comprising cations and anions comprises dispersing the functionalized diamond nanoparticles in an ionic liquid having a cation having a formula selected from the group consisting of:

13. The method of claim 1, further comprising covalently bonding one or more molecular groups to outer surfaces of a plurality of diamond nanoparticles to form the functionalized diamond nanoparticles.

14. The method of claim 1, wherein electrochemically depositing a coating over the substrate comprises forming an abrasion-resistant coating over the substrate.

15. The method of claim 1, wherein:

dispersing functionalized diamond nanoparticles in an ionic liquid comprising cations and anions comprises dispersing functionalized diamond nanoparticles in an ionic liquid comprising aluminum ions; and

electrochemically depositing a coating over the substrate comprises forming aluminum by reduction of the aluminum ions in the deposition composition.

16. The method of claim 1, wherein electrochemically depositing a coating over the substrate comprises depositing a coating over the substrate to have a higher number density of the functionalized diamond nanoparticles proximate the substrate than distal from the substrate.

17. A method of coating a substrate by electrodeposition, comprising:

disposing a deposition fluid in a container, the deposition fluid comprising;

a plurality of functionalized diamond nanoparticles, wherein the functionalized diamond nanoparticles comprise anionic functional groups and cationic functional groups, at least one functional group selected from the group consisting of carboxy, epoxy, ether, ketone, amine, hydroxy, alkoxy, alkyl, aryl, aralkyl, alkaryl, lactone, polymeric groups, oligomeric groups, quaternary ammonium groups, quaternary phosphonium groups, tertiary sulfonium groups, alkyl pyridinium groups, primary amines, secondary amines, tertiary amines, aminoethyl, dimethylaminoethyl, diethylaminoethyl, guanidinium, and imidazolium;

a plurality of anions;

a plurality of metal ions; and

an ionic liquid comprising a polymerizable ionic liquid and a non-polymerizable ionic liquid;

disposing a surface of a substrate in the container in contact with the deposition fluid;

providing a net positive charge to the plurality of functionalized diamond nanoparticles through covalent modification of the functionalized diamond nanoparticles with the ionic liquid or by polymerization of the ionic liquid on a surface of the functionalized diamond nanoparticles; and

electrochemically depositing a coating on the substrate, the coating comprising;

a metal formed from the metal ions; and

the functionalized diamond nanoparticles.

18. The method of claim 17, wherein the deposition fluid further comprises a buffer.