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

• US 7,510,760 B2
• Filed: 03/07/2005
• Issued: 03/31/2009
• 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: Boardof Trustees of The University of Arkansas
• Inventors: Brown, William D., Jiang, Wenping, Malshe, Ajay P.
• Primary Examiner(s): TURNER, ARCHENE A
• Application Number:
  US11/074,597
• Publication Number:
  US 20060199013A1
• Time in Patent Office: 1,485 Days
• Field of Search: 428/212, 428/408, 428/697, 428/698, 428/699, 428/701, 428/702, 428/704, 513/07, 513/09
• US Class Current: 428/212
• 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 periodic distribution of protrusions, wherein each of said protrusions is between 0.01 micrometer and 50 micrometers,

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

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

6. The coated article of claim 1, wherein the coated article is a tool comprising a work surface, and wherein the work surface is the substrate.

7. The coated article of claim 6, wherein said base phase comprises a nitride and said infiltrate phase comprises a nitride different than the nitride of the base phase.

8. The coated article of claim 7, wherein the base phase comprises cubic boron nitride.

9. The coated article of claim 7, wherein the base phase comprises cubic boron nitride, and the infiltrate phase comprises titanium nitride, titanium carbonitride, and titanium aluminum nitride.

10. The coated article of claim 7, 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 coated article of claim 10, wherein said outer surface has deposited thereon an overlay comprising at least one of the group consisting of MoS₂, ZnO, polytetrafluoroethylene (PTFE), a combination of MoS₂+ZnO, a combination of PTFE+MoS₂, and a combination of PTFE+ZnO₂A₁S₂, and any combination thereof, wherein at least the endmost region of each protrusion is free of said overlay.

12. The coated article of claim 11, wherein said tool is a metal machining tool.

13. A coated article comprising a substrate and a coating, said coating comprising individually-over-coated particles, the individually-over-coated particles having an average particle size of less than 1 micron and the individually-over-coated particles comprising base particles coated with supplement particles,

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.

14. The coated article of claim 13, wherein said article is a particle.

15. The coated article of claim 13, wherein said coating comprising individually-over-coated particles has a textured outer surface.

16. The coated article of claim 13, wherein said article is a tool, and wherein said base particles are ZnO and said supplement particles are MoS₂.

17. The coated article of claim 13, wherein the base particles are coated with a continuous layer of supplement particles.

18. The coated article of claim 13, wherein the base particles are coated with a discontinuous layer of supplement particles.

19. The coated article of claim 13, wherein the base particles are coated with multiple layers of supplement particles.

20. The coated article of claim 13, wherein the coating comprises more than one type of individually-over-coated particle.

21. 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 periodic distribution of protrusions, wherein each of said protrusions is between 0.01 micrometer and 50 micrometers,

wherein said composite layer comprises a base phase and an infiltrate phase, said base phase contacting said substrate and 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, silicon, nitrides, steel, carbonitrides, borides, sulphides, chalcogenides, oxides, and suicides.