Aluminized Composite Coating for Uniform Coloring of Metallic Materials

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Solution Overview

Problem

Current methods for anodizing stainless steel, titanium alloys, and recycled aluminum face challenges in achieving durability, hue consistency, and various colors, with issues such as surface defects, impurities affecting dye-coloring, and difficulty in controlling the thickness of aluminum coatings.

Innovation Solution

The development of an aluminized composite with a base material, a diffusion layer, and an aluminum layer, where the aluminum layer is joined to the base material using a combination of adhesive bonding and local heating, such as resistance spot welding or friction stir welding, to create a coherent interface without gaps, allowing for uniform coloring.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If aluminum melt dipping is used for aluminization, then corrosion resistance is improved, but the diffusion layer contains harmful elements that affect anodized dye-coloring

Engineering Contradiction:

Improvecorrosion resistanceVSAvoidharmful elements in diffusion layer affecting coloring

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The harmful elements (Fe, Si, Mn) are extracted from the aluminum melt before dipping, resulting in a purified aluminum coating that does not contain harmful elements affecting anodized dye-coloring, while still maintaining corrosion resistance through the aluminum coating itself

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The aluminum melt is purified in advance by removing harmful elements through filtration or electrostatic separation before the dipping process, ensuring that the resulting coating and diffusion layer are free from elements that would interfere with subsequent coloring operations

Inventive Principle:

Principle #10Preliminary action

2Area of stationary object

If spray forming is used for aluminization, then surface coverage is improved, but productivity decreases and surface defects increase

Engineering Contradiction:

Improvesurface coverageVSAvoidtact time and productivity

Core Design Contradiction:

Area of stationary objectVSProductivity

Solution Approach 1:

The mechanical spray forming process is replaced with an electrostatic or electromagnetic field-based deposition process, where charged aluminum particles are accelerated and deposited onto the substrate, achieving both complete surface coverage and high production speed without the defects associated with mechanical spraying

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If aluminum melt dipping is used, then aluminum coating can be applied efficiently, but the high temperature makes it difficult to control aluminum melt viscosity

Engineering Contradiction:

Improvecoating application efficiencyVSAvoidaluminum melt temperature control

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The aluminum melt temperature is reduced from conventional high temperatures to a lower range (500-700°C), which maintains adequate fluidity for coating application while improving viscosity control and reducing energy consumption, achieved through the use of purified aluminum powder or foil as feedstock

Inventive Principle:

Principle #35Parameter changes

4Ease of manufacture

If cold spraying is used for aluminization, then coating application is simplified, but surface defects such as voids and cracks are generated

Engineering Contradiction:

Improvecoating application simplicityVSAvoidsurface quality free from defects

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The aluminum coating is applied in a solid or semi-solid state through controlled deposition rather than molten spray, avoiding the rapid cooling and solidification process that creates voids and cracks, while still achieving adequate adhesion through surface preparation and controlled bonding

Inventive Principle:

Principle #36Phase transitions

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach enables the production of aluminized composites with improved bonding quality, cosmetic appeal, and enhanced tensile strength, facilitating effective dye-coloring and maintaining the desired mechanical properties.

Implementation Method 1

a first portion of the base material is adhesively bonded to a first portion of the aluminum layer in the contact region

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Implementation Method 2

The stack of layers is heated to a first elevated temperature for a first period of time to join the aluminum layer to the base material

Methodology Applied

Scientific EffectLocal heating: Heating

Implementation Method 3

A rather wide diffusion layer formed in the dipping usually contains harmful elements against anodized dye-coloring

Methodology Applied

Scientific EffectDiffusion: Diffusion

Implementation Method 4

local heating, such as resistance spot welding or friction stir welding

Methodology Applied

Scientific EffectResistance welding: Welding

Implementation Method 5

local heating, such as resistance spot welding or friction stir welding

Methodology Applied

Scientific EffectFriction welding: Friction Welding

Data Source

PatentUS11345121B2Coloring of metallic materials coated with aluminum

Publication Date: 2022.05.31 APPLE INC

AI summary

The disclosure provides an aluminized composite including a base material. The aluminized composite may also include a diffusion layer disposed over the base material. The aluminized composite may further include an aluminum material disposed over the diffusion layer.