Metallic Coating Thickness Control for Cost-Effective Corrosion Protection

The patent applies high corrosion-resistant material only to the surface coating layer rather than the entire component. The base material can be less expensive while the expensive corrosion-resistant alloy is confined to a thin surface layer (typically 0.5-5 micrometers), achieving corrosion protection where needed without the full cost of using expensive alloy throughout the entire part.

The patent transforms the material state through severe plastic deformation and shear-assisted processing, changing the microstructure and properties of the coating material in place. This allows the use of materials that would be difficult to work with in traditional forms, enabling cost-effective application of high-performance alloys through processes like ShAPE (Shear-Assisted Processing and Extrusion).

The patent replaces traditional complex mechanical processing methods with shear-assisted processing and extrusion techniques. The ShAPE process uses controlled shear forces to achieve precise grain structure control and material densification without requiring complex multi-step mechanical working, reducing manufacturing complexity while maintaining microstructural control.

The patent uses shear-assisted processing to fundamentally change the material's microstructural parameters through controlled plastic deformation. This creates a refined grain structure with improved corrosion resistance without requiring the complex heat treatment and multi-stage processing that would otherwise be needed to achieve similar microstructural control.