Corrosion-resistant fuel tank

• US 6,858,322 B2
• Filed: 05/09/2003
• Issued: 02/22/2005
• 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:
  US10/434,641
• Publication Number:
  US 20030219620A1
• 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: 428/648
• 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 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 tin-zinc alloy which forms two phases upon cooling and which resists corrosion by petroleum products, said carbon steel strip having an average thickness of about 127-5080 microns prior to coating with said tin-zinc alloy, said carbon steel strip including a plated nickel layer on at least one surface of said carbon steel metal strip prior to said tin-zinc alloy being applied to said carbon steel metal strip, said nickel layer having an average thickness of less than about 3 microns, said carbon steel metal strip including a hot dipped coating of said tin-zinc alloy by at least partial immersion in molten tin-zinc alloy which at least partially forms a heat created intermetallic layer between said carbon steel metal strip and said corrosion resistant tin-zinc alloy, said tin-zinc alloy comprising zinc and a majority of tin and having a tin plus zinc content of at least about 95 weight percent, said zinc content less than about 30 weight percent, said tin-zinc alloy having an average coating thickness of about 2.5-1270 microns, said average coating thickness of said tin-zinc alloy being greater than the average coating thickness of said plated nickel layer, said heat created intermetallic layer including iron, manganese, nickel, tin and zinc.

2. The corrosion-resistant petroleum receptacle as defined in claim 1, wherein said tin-zinc alloy includes at least one metal additive selected from the group consisting of copper, lead, magnesium, manganese, nickel, silicon, titanium, and mixtures thereof.

3. The corrosion-resistant petroleum receptacle as defined in claim 2, wherein said tin-zinc alloy includes copper.

4. The corrosion-resistant petroleum receptacle as defined in claim 2, wherein said tin-zinc alloy includes magnesium.

5. The corrosion-resistant petroleum receptacle as defined in claim 2, wherein said tin-zinc alloy includes manganese.

6. The corrosion-resistant petroleum receptacle as defined in claim 2, wherein said tin-zinc alloy includes nickel.

7. The corrosion-resistant petroleum receptacle as defined in claim 2, wherein said tin-zinc alloy includes silicon.

8. The corrosion-resistant petroleum receptacle as defined in claim 2, wherein said tin-zinc alloy includes titanium.

9. The corrosion-resistant petroleum receptacle as defined in claim 2, wherein said tin-zinc alloy includes lead.

10. The corrosion-resistant petroleum receptacle as defined in claim 2, wherein said tin-zinc alloy includes aluminum.

11. 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 tin-zinc alloy which upon cooling forms a two phase alloy which resists corrosion by petroleum products, said carbon steel strip having an average thickness of about 127-5080 microns prior to coating with said tin-zinc alloy, said carbon steel strip including a plated nickel layer on at least one surface of said carbon steel metal strip prior to said tin-zinc alloy being applied to said carbon steel metal strip, said nickel layer having an average thickness of less than about 3 microns, said carbon steel metal strip including a hot dipped coating of said tin-zinc alloy by at least partial immersion in molten tin-zinc alloy which at least partially forms a heat created intermetallic layer between said carbon steel metal strip and said tin-zinc alloy, said tin-zinc alloy comprising zinc and a majority of tin and having a tin plus zinc content of at least about 95 weight percent, said zinc content in said corrosion-resistant tin-zinc alloy being less than about 30 weight percent, said tin-zinc alloy having an average coating thickness of about 2.5-1270 microns, said average coating thickness of said tin-zinc alloy being greater than the average coating thickness of said plated nickel layer, said tin-zinc alloy including manganese, said heat created intermetallic layer including iron, manganese, nickel, tin and zinc.

12. The corrosion-resistant petroleum receptacle as defined in claim 11, wherein said heat created intermetallic layer includes at least one additional metal selected from the group consisting of aluminum, copper, lead, magnesium, silicon, titanium and mixtures thereof.

13. The corrosion-resistant petroleum receptacle as defined in claim 12, wherein said heat created intermetallic layer includes at least one metal selected from the group consisting of copper, lead, silicon and mixtures thereof.

14. The corrosion-resistant petroleum receptacle as defined in claim 12, wherein said tin-zinc alloy includes at least one metal additive selected from the group consisting of aluminum, copper, lead, magnesium, silicon, titanium and mixtures thereof.

15. The corrosion-resistant petroleum receptacle as defined in claim 13, wherein said tin-zinc alloy includes at least one metal additive selected from the group consisting of copper, lead, silicon and mixtures thereof.