Rare-Earth Corrosion-Resistant Laminate With Gradient Crystallinity
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Solution Overview
Problem
Existing corrosion-resistant members made of amorphous materials exhibit poor corrosion resistance and bonding strength between the base and the film.
Innovation Solution
A laminate body structure is introduced, comprising a base and a first layer made of a rare earth element compound with varying crystallinity, where the region close to the base has lower crystallinity than the region farther from the base, enhancing corrosion resistance and bonding strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an amorphous film is used for corrosion resistance, then the film can be formed on the base, but the corrosion resistance and bonding strength are poor
Solution Approach 1:
The patent applies local quality by creating a gradient crystallinity structure within the film layer. The region close to the base has lower crystallinity (more amorphous) to ensure strong bonding with the base, while the region far from the base has higher crystallinity to provide excellent corrosion resistance. This spatial variation in material structure resolves the contradiction between bonding strength and corrosion resistance.
Solution Approach 2:
The patent uses composite materials by combining crystalline and amorphous phases within the same film layer. The film contains both amorphous regions (providing bonding strength) and crystalline regions (providing corrosion resistance), creating a composite structure that simultaneously achieves both desired properties.
2Reliability
If a crystalline film is used to improve corrosion resistance, then corrosion resistance improves, but bonding strength between base and film deteriorates
Solution Approach 1:
The patent applies local quality by creating a gradient crystallinity structure within the film layer. The region close to the base has lower crystallinity (more amorphous) to ensure strong bonding with the base, while the region far from the base has higher crystallinity to provide excellent corrosion resistance. This spatial variation in material structure resolves the contradiction between bonding strength and corrosion resistance.
Solution Approach 2:
The patent uses composite materials by combining crystalline and amorphous phases within the same film layer. The film contains both amorphous regions (providing bonding strength) and crystalline regions (providing corrosion resistance), creating a composite structure that simultaneously achieves both desired properties.
3Ease of manufacture
If the film is made entirely amorphous for ease of formation, then formation is easier, but corrosion resistance and bonding strength are poor
Solution Approach 1:
The patent applies local quality by creating a gradient crystallinity structure within the film layer. The region close to the base has lower crystallinity (more amorphous) to ensure strong bonding with the base, while the region far from the base has higher crystallinity to provide excellent corrosion resistance. This spatial variation in material structure resolves the contradiction between bonding strength and corrosion resistance.
Solution Approach 2:
The patent uses composite materials by combining crystalline and amorphous phases within the same film layer. The film contains both amorphous regions (providing bonding strength) and crystalline regions (providing corrosion resistance), creating a composite structure that simultaneously achieves both desired properties.
Data Source
AI summary
A corrosion-resistant member according to the present disclosure is a laminate body including a base and a first layer layered on the base. The first layer is composed of a rare earth element compound containing, as a main constituent, a rare earth element that is a metal element. In the first layer, a crystallinity of a region close to the base is lower than a crystallinity of a region far from the base. A corrosion-resistant member according to the present disclosure is a laminate body including a base, a compound layer layered on the base and composed of a metal element M, and a first layer layered on the compound layer. The first layer is composed of a rare earth element compound containing, as a main constituent, a rare earth element that is a metal element. The compound layer has a uniform crystallinity. In the first layer, a crystallinity of a region close to the base is lower than a crystallinity of a region far from the base.