High-ductility Periodic Variable Alloy Protective Film
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High-vacuum direct current magnetron sputtering films made from single metals or alloys often suffer from brittleness, leading to cracking during thermal expansion and contraction, which compromises their bonding with organic coatings and appearance quality.
Innovation Solution
A high-ductility periodic variable alloy protective film is formed using a NiCr alloy layer and pure Cr targets in a high-vacuum environment, with a layered structure comprising a metal or non-metal substrate, a high-gloss organic resin coating, and a transparent resin film, optimized through specific pretreatment, sputtering, and curing processes to enhance bonding and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single-metal or single-alloy high-vacuum direct current magnetron sputtering film is used to meet corrosion resistance standards, then corrosion resistance is improved, but the film becomes brittle and cracks during thermal expansion and contraction
Solution Approach 1:
The patent applies composite materials by creating a multi-layer alloy film structure consisting of at least three layers with different Ni-Cr compositions. The film combines a Cr-rich layer (60-80 wt% Cr) for corrosion resistance, a Ni-rich layer (60-80 wt% Ni) for ductility, and an intermediate layer, forming a composite structure that achieves both corrosion resistance and flexibility to prevent cracking during thermal cycling.
Solution Approach 2:
The patent implements local quality by varying the Ni-Cr composition at different positions within the film thickness direction. Each layer has a specific composition optimized for its function: the Cr-rich layer provides corrosion resistance at the surface, while the Ni-rich layer provides ductility closer to the substrate, and the intermediate layer provides a transition zone. This spatial variation in composition resolves the contradiction between corrosion resistance and ductility.
2Strength
If the sputtering film is well combined with upper and lower organic coatings and cured, then coating bonding is improved, but thermal expansion and contraction produce stress that causes cracking
Solution Approach 1:
The patent applies parameter changes by systematically varying the Ni-Cr composition ratio across different layers of the film. The composition parameters are optimized to achieve specific mechanical properties: the Cr-rich layer (60-80 wt% Cr) provides corrosion resistance, the Ni-rich layer (60-80 wt% Ni) provides ductility and stress absorption, and the intermediate layer provides a transition. This parameter optimization enables the film to maintain strong bonding with organic coatings while absorbing thermal stress to prevent cracking.
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
The solution eliminates residual stress, improves film ductility, bonding strength, and corrosion resistance, preventing cracking and achieving a bright metallic appearance while meeting automotive standards.
Implementation Method 1
The high-vacuum direct current magnetron sputtering is such a method that working gas is ionized in a vacuum chamber, the ionized ions bombard a metal target at a high speed under the mixed field action of an electric field and a magnetic field, and the metal atoms or ions on the target splash out and are deposited and sputtered on the surface of a workpiece
Implementation Method 2
At present, the surface treatment by physical vapor deposition (PVD) mainly includes evaporation, plasma multi-arc sputtering, and high-vacuum direct current magnetron sputtering
Data Source
AI summary
The disclosure provides a metal protective layer, sequentially comprising an organic powder coating, a high-gloss organic coating, a ductile periodic variable alloy protective film and a transparent powder coating, wherein the base powder layer is an epoxy resin or pure polyester powder coating; the high-gloss organic coating is an epoxy resin powder coating, a polyester powder coating, or a polybutadiene organic coating; the ductile periodic variable alloy protective film is formed by direct current magnetron sputtering with two targets in a high vacuum environment, and the material of the targets is composed of a Ni—Cr alloy layer and pure Cr; and the transparent powder layer is an acrylic powder coating or a polyester transparent powder coating.