Corrosion resistant aluminum alloy substrates and methods of producing the same
First Claim
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1. An aluminum alloy product comprising:
- (A) an aluminum alloy base having an electrochemically formed porous sulfate-phosphate oxide zone, the porous sulfate-phosphate oxide zone having a plurality of pores;
(i) wherein the ratio of sulfur atoms to phosphorous atoms in the porous sulfate-phosphate oxide zone is from about 5;
1 to about 100;
1; and
(ii) wherein the porous sulfate-phosphate oxide zone has a thickness of at least about 5 microns; and
(B) a silicon-containing polymer zone coupled to the electrochemically formed porous sulfate-phosphate oxide zone;
(i) wherein the silicon-containing polymer zone comprises a coating portion on a surface of the aluminum alloy base; and
(ii) wherein the silicon-containing polymer zone comprises a silicon polymer having a backbone of the formula —
Si—
X—
Si—
, wherein X is either N or O; and
(iii) wherein at least some of the silicon polymer is contained within at least some of the pores of the porous sulfate-phosphate oxide zone.
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Abstract
Aluminum alloy products comprising an aluminum alloy base and a sulfate-phosphate oxide zone integral therewith are disclosed. Methods of making the same are also disclosed.
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Citations
15 Claims
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1. An aluminum alloy product comprising:
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(A) an aluminum alloy base having an electrochemically formed porous sulfate-phosphate oxide zone, the porous sulfate-phosphate oxide zone having a plurality of pores; (i) wherein the ratio of sulfur atoms to phosphorous atoms in the porous sulfate-phosphate oxide zone is from about 5;
1 to about 100;
1; and(ii) wherein the porous sulfate-phosphate oxide zone has a thickness of at least about 5 microns; and (B) a silicon-containing polymer zone coupled to the electrochemically formed porous sulfate-phosphate oxide zone; (i) wherein the silicon-containing polymer zone comprises a coating portion on a surface of the aluminum alloy base; and (ii) wherein the silicon-containing polymer zone comprises a silicon polymer having a backbone of the formula —
Si—
X—
Si—
, wherein X is either N or O; and(iii) wherein at least some of the silicon polymer is contained within at least some of the pores of the porous sulfate-phosphate oxide zone.
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2. The aluminum alloy product of claim 1, wherein the pores of the porous sulfate-phosphate oxide zone have an average pore size of at least about 10 nm.
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3. The aluminum alloy product of claim 2, wherein the average pore size is not greater than about 15 nm.
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4. The aluminum alloy product of claim 1, wherein the thickness of the porous sulfate-phosphate oxide zone is not greater than about 25 microns.
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5. The aluminum alloy product of claim 1, wherein the aluminum alloy is a 6061 series alloy.
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6. The aluminum alloy product of claim 5, wherein the aluminum alloy product is a forged product.
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7. The aluminum alloy product of claim 6, wherein the aluminum alloy product is a wheel product.
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8. The aluminum alloy product of claim 1, wherein the aluminum alloy product is capable of passing a copper-accelerated acetic acid salt spray test (CASS), as defined by ASTM B368-97(2003)e1.
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9. The aluminum alloy product of claim 1, wherein the coating portion of the silicon-containing polymer zone has a thickness of at least about 8 micron.
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10. The aluminum alloy product of claim 1, wherein the coating portion of the silicon-containing polymer zone has a thickness of at least about 35 micron.
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11. The aluminum alloy product of claim 10, wherein the coating portion of the silicon-containing polymer is substantially crack-free.
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12. The aluminum alloy product of claim 11, wherein the polymer of the silicon-containing polymer zone is polysilazane.
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13. The aluminum alloy product of claim 1, wherein the ratio of sulfur atoms to phosphorous atoms in the sulfate-phosphate oxide zone is from about 10:
- 1 to about 75;
1.
- 1 to about 75;
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14. The aluminum alloy product of claim 1, wherein the ratio of sulfur atoms to phosphorous atoms in the sulfate-phosphate oxide zone is from about 20:
- 1 to about 75;
1.
- 1 to about 75;
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15. The aluminum alloy product of claim 1, wherein the sulfate-phosphate oxide zone consists essentially of sulfur, phosphorous, oxygen and aluminum.
Specification