Corrosion-resistant coated metal and method for making the same

• US 6,811,891 B2
• Filed: 01/17/2003
• Issued: 11/02/2004
• 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:
  US10/346,262
• Publication Number:
  US 20030170485A1
• Time in Patent Office: 655 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: 428/646
• 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 to maintain 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, said corrosion-resistant carbon steel metal strip including a hot dipped coating of said corrosion-resistant metal alloy, said corrosion-resistant metal alloy comprising tin, zinc and at least an effective amount of at least one metal additive to positively affect the mechanical properties of said corrosion-resistant metal alloy, the chemical properties of said corrosion-resistant alloy and combinations thereof, at least about 99 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 corrosion-resistant metal alloy forming a multi-phase alloy when solidified and said tin and said zinc forming a phase in said corrosion-resistant metal alloy, said metal additive including copper, magnesium, manganese, nickel, silicon, titanium and mixtures thereof, said corrosion-resistant metal alloy having a coating thickness of up to about 0.003 inch.

2. The corrosion-resistant petroleum receptacle as defined in claim 1, including a plated nickel layer on said top and bottom surface of said carbon steel metal strip prior to said corrosion-resistant metal alloy being applied to said carbon steel metal strip, said nickel layer having a thickness of up to about 3 microns, said coating thickness of said corrosion-resistant metal alloy being greater than the thickness of said plated nickel layer.

3. The corrosion-resistant petroleum receptacle as defined in claim 1, wherein said corrosion-resistant metal alloy includes lead.

4. The corrosion-resistant petroleum receptacle as defined in claim 2, wherein said corrosion-resistant metal alloy includes lead.

5. The corrosion-resistant petroleum receptacle as defined in claim 3, wherein said lead has a content of less than about 0.05 weight percent.

6. The corrosion-resistant petroleum receptacle as defined in claim 1, wherein said metal additive includes copper.

7. The corrosion-resistant petroleum receptacle as defined in claim 1, wherein said metal additive includes silicon.

8. The corrosion-resistant petroleum receptacle as defined in claim 1, wherein said metal additive includes magnesium.

9. The corrosion-resistant petroleum receptacle as defined in claim 1, wherein said metal additive includes manganese.

10. The corrosion-resistant petroleum receptacle as defined in claim 1, wherein said metal additive includes nickel.

11. The corrosion-resistant petroleum receptacle as defined in claim 1, wherein said metal additive includes titanium.

12. The corrosion-resistant petroleum receptacle as defined in claim 1, wherein said zinc content is at least about 10 weight percent.

13. The corrosion-resistant petroleum receptacle as defined in claim 4, wherein said zinc content is at least about 10 weight percent.

14. Corrosion-resistant petroleum receptacle comprising at least one shell member, said at least one shell member including a metal strip having a top and bottom surface coated with a corrosion-resistant metal alloy which resists corrosion by petroleum products, said strip having an average thickness of less than about 0.2 inch, said corrosion-resistant metal strip including a coating of said corrosion-resistant metal alloy, said corrosion-resistant metal alloy comprising tin, zinc and at least an effective amount of at least one metal additive to positively affect the mechanical properties of said corrosion-resistant metal alloy, the chemical properties of said corrosion-resistant alloy and combinations thereof, at least about 95 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 corrosion-resistant metal alloy forming a multi-phase alloy when solidified and said tin and said zinc forming a phase in said corrosion-resistant metal alloy, said metal additive including chromium, copper, magnesium, manganese, molybdenum, nickel, silicon, titanium and mixtures thereof, said corrosion-resistant metal alloy having an average coating thickness of up to about 0.003 inch.

15. The corrosion-resistant petroleum receptacle as defined in claim 14, including a plated nickel layer on said top and bottom surface of said metal strip prior to said corrosion-resistant metal alloy being applied to said metal strip, said nickel layer having an average thickness of up to about 3 microns, said coating thickness of said corrosion-resistant metal alloy being greater than the thickness of said plated nickel layer.

16. The corrosion-resistant petroleum receptacle as defined in claim 14, wherein said corrosion-resistant metal alloy includes lead.

17. The corrosion-resistant petroleum receptacle as defined in claim 15, wherein said corrosion-resistant metal alloy includes lead.

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

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

20. The corrosion-resistant petroleum receptacle as defined in claim 17, wherein said metal additive includes copper.

21. The corrosion-resistant petroleum receptacle as defined in claim 14, wherein said metal additive includes silicon.

22. The corrosion-resistant petroleum receptacle as defined in claim 15, wherein said metal additive includes silicon.

23. The corrosion-resistant petroleum receptacle as defined in claim 20, wherein said metal additive includes silicon.

24. The corrosion-resistant petroleum receptacle as defined in claim 14, wherein said metal additive includes manganese.

25. The corrosion-resistant petroleum receptacle as defined in claim 15, wherein said metal additive includes manganese.

26. The corrosion-resistant petroleum receptacle as defined in claim 23, wherein said metal additive includes manganese.

27. The corrosion-resistant petroleum receptacle as defined in claim 14, wherein said metal additive includes magnesium.

28. The corrosion-resistant petroleum receptacle as defined in claim 15, wherein said metal additive includes magnesium.

29. The corrosion-resistant petroleum receptacle as defined in claim 26, wherein said metal additive includes magnesium.

30. The corrosion-resistant petroleum receptacle as defined in claim 14, wherein said metal additive includes nickel.

31. The corrosion-resistant petroleum receptacle as defined in claim 15, wherein said metal additive includes nickel.

32. The corrosion-resistant petroleum receptacle as defined in claim 29, wherein said metal additive includes nickel.

33. The corrosion-resistant petroleum receptacle as defined in claim 14, wherein said metal additive includes titanium.

34. The corrosion-resistant petroleum receptacle as defined in claim 15, wherein said metal additive includes titanium.

35. The corrosion-resistant petroleum receptacle as defined in claim 32, wherein said metal additive includes titanium.

36. A corrosion-resistant petroleum receptacle including a metal strip having a top surface coated with a corrosion-resistant metal alloy which resists corrosion, said strip having an average thickness of less than about 0.2 inch, said corrosion-resistant metal alloy comprising tin, zinc and at least an effective amount of at least one metal component to positively affect the mechanical properties of said corrosion-resistant metal alloy, the chemical properties of said corrosion-resistant alloy and combinations thereof, at least about 95 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 corrosion-resistant metal alloy forming a multi-phase alloy when solidified and said tin and said zinc forming a phase in said corrosion-resistant metal alloy, said metal component including chromium, copper, magnesium, manganese, molybdenum, nickel, silicon, titanium and mixtures thereof, said corrosion-resistant metal alloy having an average coating thickness of up to about 0.003 inch.

37. The corrosion-resistant petroleum receptacle as defined in claim 36, including a plated nickel layer on said top and bottom surface of said metal strip prior to said corrosion-resistant metal alloy being applied to said metal strip, said nickel layer having an average thickness of up to about 3 microns, said coating thickness of said corrosion-resistant metal alloy being greater than the thickness of said plated nickel layer.