Corrosion-resistant coated metal and method for making the same

• US 6,652,990 B2
• Filed: 05/10/2002
• Issued: 11/25/2003
• Est. Priority Date: 03/27/1992
• Status: Expired due to Fees

• Current Assignee: Revere Copper Products, Inc.
• Original Assignee: The Louis Berkman Company
• Inventors: Zamanzadeh, Mehrooz, Hesske, Nicholas R., Carey, Jay F. II
• Primary Examiner(s): Zimmerman, John J.
• Application Number:
  US10/144,148
• Publication Number:
  US 20030089432A1
• Time in Patent Office: 564 Days
• Field of Search: 428/646, 428/647, 428/648, 428/939, 428/679, 220/562, 220/567.2, 206/524.3
• US Class Current: 428/647
• CPC Class Codes: B23K 35/262 Sn as the principal constituent
• CPC Class Codes: B23K 35/282 Zn as the principal constituent
• CPC Class Codes: B32B 15/01 all layers being exclusively metallic making layered metal workpieces by pressure cladding B23K20/22; making coatings with a metallic material characterised by its composition C23C30/00
• CPC Class Codes: B32B 15/011 all layers being formed of iron alloys or steels
• CPC Class Codes: B32B 15/013 one layer being formed of an iron alloy or steel, another layer being formed of a metal other than iron or aluminium
• CPC Class Codes: B32B 15/015 the said other metal being copper or nickel or an alloy thereof
• CPC Class Codes: C22C 13/00 Alloys based on tin
• CPC Class Codes: C22C 18/00 Alloys based on zinc
• CPC Class Codes: C22C 30/00 Alloys containing less than 50% by weight of each constituent
• CPC Class Codes: C22C 30/04 containing tin or lead
• CPC Class Codes: C22C 30/06 containing zinc
• CPC Class Codes: C23C 2/0034 Details related to elements immersed in bath
• CPC Class Codes: C23C 2/0035 Means for continuously moving substrate through, into or out of the bath C23C2/00344 takes precedence
• CPC Class Codes: C23C 2/0036 Crucibles
• CPC Class Codes: C23C 2/0038 characterised by the pre-treatment chambers located immediately upstream of the bath or occurring locally before the dipping process
• CPC Class Codes: C23C 2/02 Pretreatment of the material to be coated, e.g. for coating on selected surface areas C23C2/30 takes precedence
• CPC Class Codes: C23C 2/024 by cleaning or etching
• CPC Class Codes: C23C 2/026 Deposition of sublayers, e.g. adhesion layers or pre-applied alloying elements or corrosion protection
• CPC Class Codes: C23C 2/06 Zinc or cadmium or alloys based thereon
• CPC Class Codes: C23C 2/08 Tin or alloys based thereon
• CPC Class Codes: C23C 2/28 : Thermal after-treatment, e.g. treatment in oil bath
• CPC Class Codes: C23C 2/40 : Plates; Strips
• CPC Class Codes: C23C 26/00 : Coating not provided for in groups C23C2/00 - C23C24/00
• CPC Class Codes: C23C 28/021 : including at least one metal alloy layer
• CPC Class Codes: C23C 28/023 : only coatings of metal elements only
• CPC Class Codes: C23C 28/025 : with at least one zinc-based layer
• CPC Class Codes: 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
• CPC Class Codes: Y10S 428/939 : Molten or fused coating
• CPC Class Codes: Y10T 428/12708 : Sn-base component
• CPC Class Codes: Y10T 428/12715 : Next to Group IB metal-base component
• CPC Class Codes: Y10T 428/12722 : Next to Group VIII metal-base component
• CPC Class Codes: Y10T 428/12792 : Zn-base component
• CPC Class Codes: Y10T 428/12799 : Next to Fe-base component [e.g., galvanized]
• CPC Class Codes: Y10T 428/12937 : Co- or Ni-base component next to Fe-base component

Abstract

A corrosion-resistant coated brass metal coated with a corrosion resistant alloy. The corrosion resistant alloy is a tin metal alloy or a tin and zinc metal alloy. The corrosion resistant metal alloy may also include one or more metal additives to improve the coating process and/or to alter the properties of the tin or tin and zinc metal alloy.

Claims

1. A corrosion resistant petroleum receptacle comprising at least one shell member that includes a seal that maintains fluid within an interior of said petroleum receptacle, said seal including a weld, a solder, bonding, and combinations thereof, said at least one shell member including a carbon steel metal strip having a top and bottom surface coated with a corrosion resistant metal alloy which resists corrosion by petroleum products, said carbon steel strip having a thickness of less than about 0.2 inch prior to coating with said corrosion resistant metal alloy, said corrosion resistant carbon steel metal strip including a plated nickel layer on said top and bottom surface and a hot dipped coating of said corrosion resistant metal alloy applied over said plated nickel layer, said nickel layer having a thickness of up to about 3 microns, said corrosion resistant metal alloy comprising at least about 99.5 weight percent tin plus zinc, said zinc content about 7-30 weight percent, said corrosion resistant metal alloy including lead and at least an effective amount of at least one metal additive to strengthen said metal alloy, to increase the pliability of said metal alloy and combinations thereof, said lead content is less than about 0.05 weight percent, said metal additive content is up to about 0.5 weight percent, said metal additive includes copper, said corrosion resistant metal alloy having a coating thickness of less than about 0.003 inch.

2. The corrosion resistant petroleum receptacle as defined in claim 1, wherein said metal additive includes antimony, bismuth, and combinations thereof.

3. A metal strip having a top and bottom surface coated with a corrosion resistant metal alloy formulated for use in making drawn components for petroleum receptacles and which resists corrosion by petroleum products, said metal strip formed of carbon steel and having a thickness of less than about 0.2 inch, said metal strip having a hot dipped coating of said corrosion resistant metal alloy on said top and bottom surface, said corrosion resistant metal alloy comprising tin, zinc, lead and at least an effective amount of at least one metal additive to strengthen said metal alloy, to increase the pliability of said metal alloy and combinations thereof, at least about 99.5 weight percent of said corrosion resistant metal alloy comprised of tin and zinc, said zinc content of said corrosion resistant metal alloy being up to about 30 weight percent, said metal additive including antimony, bismuth, copper and mixtures thereof, said corrosion resistant metal alloy having a coating thickness of less than about 0.003 inch.

4. The metal strip as defined in claim 3, wherein said lead content of said corrosion resistant metal alloy is less then about 0.05 weight percent.

5. The metal strip as defined in claim 3, wherein said metal strip includes a plated nickel layer on said top and bottom surface prior to said corrosion resistant metal alloy being applied to said metal strip, said nickel layer having a thickness of up to about 3 microns.

6. The metal strip as defined in claim 4, wherein said metal strip includes a plated nickel layer on said top and bottom surface prior to said corrosion resistant metal alloy being applied to said metal strip, said nickel layer having a thickness of up to about 3 microns.

7. The metal strip as defined in claim 3, wherein said corrosion resistant metal alloy includes about 7-12 weight percent zinc.

8. The metal strip as defined in claim 6, wherein said corrosion resistant metal alloy includes about 7-12 weight percent zinc.

9. The metal strip as defined in claim 3, wherein said metal additive includes copper.

10. The metal strip as defined in claim 8, wherein said metal additive includes copper.

11. The metal strip as defined in claim 3, wherein said metal additive includes magnesium.

12. The metal strip as defined in claim 8, wherein said metal additive includes magnesium.

13. A corrosion resistant petroleum receptacle comprising at least one shell member that includes a seal that maintains fluid within an interior of said petroleum receptacle, said seal including a weld, a solder, bonding, and combinations thereof, said at least one shell member including a carbon steel metal strip having a top and bottom surface coated with a nickel layer and a corrosion resistant metal alloy which resists corrosion by petroleum products, said carbon steel strip having a thickness of less than about 0.2 inch, said nickel layer plated on said top and bottom surface of said carbon steel metal strip and a hot dipped coating of said corrosion resistant metal alloy applied over said plated nickel layer, said nickel layer having a thickness of up to about 3 microns, said corrosion resistant metal alloy comprising tin, zinc, lead and at least an effective amount of at least one metal additive to strengthen said metal alloy, to increase the pliability of said metal alloy and combinations thereof, at least about 99.5 weight percent of said corrosion resistant metal alloy comprised of tin and zinc, said zinc content of said corrosion resistant metal alloy being up to about 30 weight percent, said metal additive including antimony, bismuth, copper and mixtures thereof, said corrosion resistant metal alloy having a coating thickness of less than about 0.003 inch.

14. The corrosion resistant petroleum receptacle as defined in claim 13, wherein said lead content of said corrosion resistant metal alloy is less than about 0.05 weight percent.

15. The corrosion resistant petroleum receptacle as defined in claim 13, wherein said metal additive includes copper.

16. The corrosion resistant petroleum receptacle as defined in claim 14, wherein said metal additive includes copper.

17. The corrosion resistant petroleum receptacle as defined in claim 13, wherein said corrosion resistant metal alloy includes about 7-12 weight percent zinc.

18. The corrosion resistant petroleum receptacle as defined in claim 15, wherein said corrosion resistant metal alloy includes about 7-12 weight percent zinc.

19. The corrosion resistant petroleum receptacle as defined in claim 13, wherein said metal additive includes magnesium.

20. The corrosion resistant petroleum receptacle as defined in claim 18, wherein said metal additive includes magnesium.

21. A corrosion resistant petroleum receptacle comprising at least one shell member that includes a seal that maintains fluid within an interior of said petroleum receptacle, said seal including a weld, a solder, bonding, and combinations thereof, said at least one shell member including a metal strip having a top and bottom surface coated with a nickel layer and a corrosion resistant metal alloy which resists corrosion by petroleum products, said metal strip having a thickness of less than about 0.2 inch prior to coating with said corrosion resistant metal alloy, said nickel layer plated on said top and bottom surface of said metal strip and a hot dipped coating of said corrosion resistant metal alloy applied over said plated nickel layer, said nickel layer having a thickness of up to about 3 microns, said corrosion resistant metal alloy comprising at least about 99.5 weight percent tin plus zinc, said zinc content about 7-30 weight percent said corrosion resistant metal alloy including at least an effective amount of lead to positively affect one or more physical properties of the tin-zinc alloy, chemical properties of the tin-zinc alloy, and combinations thereof, and at least an effective amount of at least one metal additive to positively affect one or more physical properties of the tin-zinc alloy, chemical properties of the tin-zinc alloy, and combinations thereof, said metal additive content is up to about 0.5 weight percent said metal additive including at least two of aluminum, antimony, bismuth, copper, magnesium, manganese, nickel, silicon and titanium, said corrosion resistant metal alloy having a coating thickness of less than about 0.003 inch.

22. The corrosion resistant petroleum receptacle as defined in claim 21, wherein said corrosion resistant metal alloy includes about 7-12 weight percent zinc.

23. The corrosion resistant petroleum receptacle as defined in claim 21, wherein said metal additive includes at least an effective amount of aluminum.

24. The corrosion resistant petroleum receptacle as defined in claim 22, wherein said metal additive includes at least an effective amount of aluminum.

25. The corrosion resistant petroleum receptacle as defined in claim 21, wherein said metal additive includes at least an effective amount of copper.

26. The corrosion resistant petroleum receptacle as defined in claim 24, wherein said metal additive includes at least an effective amount of copper.

27. The corrosion resistant petroleum receptacle as defined in claim 21, wherein said metal additive includes at least an effective amount of magnesium.

28. The corrosion resistant petroleum receptacle as defined in claim 26, wherein said metal additive includes at least an effective amount of magnesium.

29. The corrosion resistant petroleum receptacle as defined in claim 21, wherein said lead content of said corrosion resistant metal alloy is less than about 0.05 weight percent.

30. The corrosion resistant petroleum receptacle as defined in claim 28, wherein said lead content of said corrosion resistant metal alloy is less than about 0.05 weight percent.

31. A metal strip having a top and bottom surface coated with a corrosion resistant metal alloy formulated for use in making drawn components for petroleum receptacles and which resists corrosion by petroleum products, said metal strip having a thickness of less than about 0.2 inch prior to coating with said corrosion resistant metal alloy, said nickel layer plated on said top and bottom surface of said metal strip and a hot dipped coating of said corrosion resistant metal alloy applied over said plated nickel layer, said nickel layer having a thickness of up to about 3 microns, said corrosion resistant metal alloy comprising at least about 99.5 weight percent tin plus zinc, said zinc content about 7-30 weight percent, said corrosion resistant metal alloy including at least an effective amount of lead to positively affect one or more physical properties of the tin-zinc alloy, chemical properties of the tin-zinc alloy, and combinations thereof, and at least an effective amount of at least one metal additive to positively affect one or more physical properties of the tin-zinc alloy, chemical properties of the tin-zinc alloy, and combinations thereof, said metal additive content is up to about 0.5 weight percent, said metal additive including at least two of aluminum, antimony, bismuth, copper, magnesium, manganese, nickel, silicon and titanium, said corrosion resistant metal alloy having a coating thickness of less than about 0.003 inch.

32. The metal strip as defined in claim 31, wherein said corrosion resistant metal alloy includes about 7-12 weight percent zinc.

33. The metal strip as defined in claim 31, wherein said metal additive includes at least an effective amount of aluminum.

34. The metal strip as defined in claim 32, wherein said metal additive includes at least an effective amount of aluminum.

35. The metal strip as defined in claim 31, wherein said metal additive includes at least an effective amount of copper.

36. The metal strip as defined in claim 34, wherein said metal additive includes at least an effective amount of copper.

37. The metal strip as defined in claim 31, wherein said metal addictive includes at least an effective amount of magnesium.

38. The metal strip as defined in claim 36, wherein said metal additive includes at least an effective amount of magnesium.

39. The metal strip as defined in claim 31, wherein said lead content of said corrosion resistant metal alloy is less than about 0.05 weight percent.

40. The metal strip as defined in claim 38, wherein said lead content of said corrosion resistant metal alloy is less than about 0.05 weight percent.