Nanoparticle compositions, coatings and articles made therefrom, methods of making and using said compositions, coatings and articles

• US 20060199013A1
• Filed: 03/07/2005
• Published: 09/07/2006
• Est. Priority Date: 03/07/2005
• Status: Active Grant

• Current Assignee: The Board of Trustees of the University of Arkansas (University of Arkansas System)
• Original Assignee: The Board of Trustees of the University of Arkansas (University of Arkansas System)
• Inventors: Jiang, Wenping, Malshe, Ajay P., Brown, William D.
• Granted Patent: US 7,510,760 B2
• Time in Patent Office: Days
• US Class Current: 428/409
• CPC Class Codes: B22F 2005/002 Tools other than cutting tools
• CPC Class Codes: B22F 7/06 of composite workpieces or articles from parts, e.g. to form tipped tools B22F7/002 takes precedence
• CPC Class Codes: B26B 21/60 by the coating material
• CPC Class Codes: C23C 16/045 Coating cavities or hollow spaces, e.g. interior of tubes; Infiltration of porous substrates
• CPC Class Codes: C23C 16/34 Nitrides C23C16/303 takes precedence
• CPC Class Codes: C23C 24/00 Coating starting from inorganic powder spraying of the coating material in molten state C23C4/00; solid state diffusion C23C8/00 - C23C12/00
• CPC Class Codes: C23C 28/00 Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
• CPC Class Codes: C23C 30/005 on hard metal substrates
• CPC Class Codes: Y10T 428/24942 including components having same physical characteristic in differing degree
• CPC Class Codes: Y10T 428/30 Self-sustaining carbon mass or layer with impregnant or other layer
• CPC Class Codes: Y10T 428/31 Surface property or characteristic of web, sheet or block

Abstract

Compositions comprising nanoparticles, microparticles, and combinations thereof, the particles may be overcoated particles. Composite coatings and coated articles made therefrom, the coatings comprising mono or multi layers having a textured outer surface morphology, the layers may be continuous and/or discontinuous and may comprise different particle phases. Methods of making and using said compositions, coatings and coated articles.

Claims

1. A coated article comprising a substrate having a composite layer formed thereon,

wherein said composite layer comprises an outer surface having a texture comprising a distribution of protrusions, wherein each of said protrusions is between 0.01 and 50 micrometers,

wherein said composite layer comprises a base phase and an infiltrate phase, said base phase comprising at least one of the group consisting of diamond, silicon, nitrides, carbides, steel, carbonitrides, borides, sulphides, chalcogenides, oxides, and suicides, and said infiltrate phase comprising at least one of the group consisting of diamond, silicon, nitrides, carbides, steel, carbonitrides, borides, sulphides, chalcogenides, oxides, and silicides.

2. The coated article of claim 1, wherein the base phase comprises a nitride and the infiltrate phase comprises a nitride different than the nitride of the base phase.

3. The coated article of claim 2, wherein the base phase comprises cubic boron nitride.

4. The coated article of claim 1, wherein the base phase comprises cubic boron nitride, and the infiltrate phase comprises at least one nitride of the group consisting of titanium nitride, titanium carbonitride, and titanium aluminum nitride.

5. The coated article of claim 1, wherein said surface has deposited thereon an overlay comprising at least one of the group consisting of nitrides, carbides, steel, carbonitrides, borides, sulphides, chalcogenides, oxides, suicides, polytetrafluoroethylene, and any combination thereof, wherein at least the endmost region of each protrusion is free of said overlay.

6. A tool comprising a work surface, wherein the work surface has deposited thereon a composite layer comprises an outer surface having a texture comprising a distribution of protrusions, wherein each of said protrusions is between 0.01 and 50 micrometers,

wherein said composite layer comprises a base phase comprising at least one of the group consisting of diamond, silicon, nitrides, carbides, steel, carbonitrides, borides, sulphides, chalcogenides, oxides, and silicides, and an infiltrate phase comprising at least one of the group consisting of diamond, silicon, nitrides, carbides, steel, carbonitrides, borides, sulphides, chalcogenides, oxides, and silicides.

7. The tool of claim 7, wherein said base phase comprises a nitride and said infiltrate phase comprises a nitride different than the nitride of the base phase.

8. The tool of claim 8, wherein the base phase comprises cubic boron nitride.

9. The tool of claim 8, wherein the base phase comprises cubic boron nitride, and the infiltrate. phase comprises titanium nitride, titanium carbonitride, and titanium aluminum nitride.

10. The tool of claim 8, wherein said outer surface has deposited thereon an overlay comprising at least one of the group consisting of nitrides, carbides, steel, carbonitrides, borides, sulphides, chalcogenides, oxides, suicides, polytetrafluoroethylene, and any combination thereof wherein at least the endmost region of each protrusion is free of said overlay.

11. The tool of claim 11 wherein said outer surface has deposited thereon an overlay comprising at least one of the group consisting of MoS2, ZnO, PTFE, a combination of MoS2+ZnO, a combination of PTFE+MoS2, and a combination of PTFE+ZnO2AIS2, and any combination thereof wherein at least the endmost region of each protrusion is free of said overlay.

12. The tool of claim 12 wherein said tool a metal machining tool.

13. A method of coating a substrate comprising the steps:

a) depositing solid particles on a substrate to form a base layer wherein said particles are in contact with the substrate, wherein said particles comprise at least one of the group consisting of diamond, silicon, nitrides, carbides, steel, carbonitrides, borides, sulphides, chalcogenides, oxides, and silicides, and

b) infiltrating said base layer with an infiltrate to form a continuous composite layer on the substrate,

wherein said composite layer comprises an outer surface having a texture comprising a distribution of protrusions, wherein each of said protrusions is between 0.01 and 50 micrometers,

wherein said infiltrate comprises at least one of the group consisting of diamond, silicon, nitrides, carbides, steel, carbonitrides, borides, sulphides, chalcogenides, oxides, and silicides.

14. The method of claim 14, wherein the base phase comprises a nitride and the infiltrate phase comprises a nitride different than the nitride of the base phase.

15. The method of claim 14, wherein in step a) the base phase is formed by electrostatic spray coating, and in step b) the composite layer is formed by at least one of the group consisting of chemical vapor infiltration (CVI), plasma enhanced CVI, physical vapor deposition (PVD), reactive PVD, and any combinations thereof.

18. The method of claim 14 wherein step a) is repeated at least once prior to performing step b).

19. The method of claim 14 further comprising the step

c) depositing onto said composite layer at least one of the group consisting of nitrides, carbides, steel, carbonitrides, borides, sulphides, chalcogenides, oxides, and suicides, polytetrafluoroethylene, and any combination thereof to form an overlay on said composite layer.

16. The method of claim 16, wherein the base phase comprises cubic boron nitride.

17. The method of claim 16, wherein the base phase comprises cubic boron nitride, and the infiltrate phase comprises at least one of the group consisting of titanium nitride, titanium carbonitride, and titanium aluminum nitride.

20. The method of claim 20 further comprising the step

d) adhering said overlay to said composite layer.

21. The method of claim 21 further comprising the step

e) selectively removing portions of said overlay to reveal portions of said composite layer.

22. A method of shaping a workpiece comprising contacting the workpiece with a tool work surface, wherein the tool work surface supports a composite layer comprises an outer surface having a texture comprising a distribution of protrusions, wherein each of said protrusions is between 0.01 and 50 micrometers, wherein said composite layer comprises a base phase comprising at least one of the group consisting of diamond, silicon, nitrides, carbides, steel, carbonitrides, borides, sulphides, chalcogenides, oxides, and suicides, and an infiltrate phase comprising at least one of the group consisting of diamond, silicon, nitrides, carbides, steel, carbonitrides, borides, sulphides, chalcogenides, oxides, and silicides.

23. The method of claim 23 wherein said outer surface has deposited thereon an overlay comprising at least one of the group consisting of nitrides, carbides, steel, carbonitrides, borides, sulphides, chalcogenides, oxides, suicides, polytetrafluoroethylene, and any combination thereof, wherein at least the endmost region of each protrusion is free of said overlay.

24. A composition comprising alloyed particles wherein said alloyed particles comprise base particles and supplement particles, where the surface of said base particles supports a coating of supplement particles, and wherein said base particles comprise at least one of the group consisting of nitrides, carbides, steel, carbonitrides, borides, sulphides, chalcogenides, oxides, and silicides, wherein said supplement particles comprise at least one of the group consisting of nitrides, carbides, steel, carbides, carbonitrides, borides, sulphides, chalcogenides, oxides, and silicides, and wherein said alloyed particles have an average particle size of less than 1 micron.

25. The composition of claim 25 wherein said coating of supplement particles is a single layer.

26. The composition of claim 26 wherein said layer is a discontinuous layer.

27. The composition of claim 26 wherein said base particles are ZnO and said supplement particles are MoS2.

28. A coated article comprising a substrate supporting a coating, wherein said coating comprises comprising alloyed particles having an average particle size of less than 1 micron, wherein said alloyed particles comprise base particles and supplement particles, where the surface of said base particles supports a coating of supplement particles, and wherein said base particles comprise at least one of the group consisting of nitrides, carbides, steel, carbonitrides, borides, sulphides, chalcogenides, oxides, and suicides, and wherein said supplement particles comprise at least one of the group consisting of nitrides, carbides, steel, carbonitrides, borides, sulphides, chalcogenides, oxides, and silicides.

29. The coated article of claim 29 wherein said article is a particle.

31. The coated article of claim 29 wherein said article is a tool, and wherein said base particles are ZnO and said supplement particles are MoS2.

30. The coated article of claim 30 wherein said coating has a textured outer surface.

32. A method for making a particle composition comprising the step of

a) combining base particles together with supplement particles to produce alloyed particles, wherein said alloyed particles have an average particle size of less than 1 micrometer, wherein said base particles comprise at least one of the group consisting of nitrides, carbides, steel, carbonitrides, borides, sulphides, chalcogenides, oxides, and silicides, and wherein said supplement particles comprise at least one of the group consisting of nitrides, carbides, steel, carbonitrides, borides, sulphides, chalcogenides, oxides, and silicides.

33. The method of claim 33 wherein the step a) combining is achieved by depositing said supplement particles on the surface of said base particles to form a coating thereon.

34. The method of claim 33 further comprising the step of

b) treating the alloyed particles to produce a metastable phase.

35. The method of claim 34 wherein the ratio of said base particles to said supplement particles is in the range of 10:

1 to 1;

10.

36. The method of claim 36 wherein said base particles are ZnO and said supplement particles are MoS2.

37. The method of claim 36 wherein said supplement particles form a discontinuous layer on the surface of said base particles.

38. A method for coating an article comprising the step

a) depositing a layer of a composition on a substrate to form a coating, wherein said composition comprises alloyed particles, wherein said alloyed particles comprise base particles and supplement particles, wherein the surface of said base particles supports a coating of supplement particles, and wherein said base particles comprise at least one of the group consisting of nitrides, carbides, steel, carbonitrides, borides, sulphides, chalcogenides, oxides, and silicides, wherein said supplement particles comprise at least one of the group consisting of nitrides, carbides, steel, carbonitrides, borides, sulphides, chalcogenides, oxides, and silicides, and wherein said alloyed particles have an average particle size of less than 1 micron.

39. The method of claim 38 wherein said base particles are ZnO and said coating particles are MoS2.

40. The method of claim 39 wherein depositing in step a) is electrostatic spray coating.

41. The method of claim 38 wherein said article is a particle.

42. The method of claim 40 wherein said article is a machining tool, and wherein said base particles are ZnO and said supplement particles are MoS2.