Composite electroplated article and process

Claim 2

A composite electroplated article comprising a body having an electrically conductive surface, an adherent first layer on said surface comprising a nickel-iron alloy having an average iron content of about 15 to about 50 percent by weight, an adherent second layer on said first layer comprising a nickel-containing plate having an average sulfur content of about 0.02 to about 0.5 percent by weight, and an adherent third layer on said second layer comprising a nickel-iron alloy having an average iron content less than that of said first layer and ranging from about 5 to about 19 percent by weight.

Claim 3

The article as defined in claim 1 further including an adherent chromium layer on said third layer.

Claim 4

The article as defined in claim 1 further including an adherent nickel-containing plate on said third layer and an adherent outer chromium plate.

Claim 5

The article as defined in claim 3 in which said nickel-containing layer over which said outer chromium plate is disposed induces micro-discontinuities in said chromium layer.

Claim 6

The article as defined in claim 1 in which said first layer is of a thickness of about 0.2 to about 2 mils, said second layer is of a thickness of about 0.005 to about 0.2 mil, and said third layer is of a thickness of about 0.2 to about 2 mils.

Claim 7

The article as defined in claim 1 in which the thickness of said first layer is about 0.5 to about 1 mil, the thickness of said second layer is about 0.05 to about 0.1 mil, and the thickness of said third layer is about 0.3 to about 1 mil.

Claim 8

The article as defined in claim 1 in which the average iron content of said third layer is at least 2 percent less than the average iron content of said first layer.

Claim 9

The article as defined in claim 1 in which the average iron content of said third layer is at least 5 percent less than the average iron content of said first layer.

Claim 10

The article as defined in claim 1 in which the average iron content of said third layer is about 50 percent of the average iron content of said first layer.

Claim 11

The article as defined in claim 1 in which the average iron content of said first layer is about 25 to about 35 percent by weight and the average iron content of said third layer is about 10 to about 14 percent by weight.

Claim 12

The article as defined in claim 1 in which the sulfur content of said first and said third layer ranges from about 0.01 to about 0.1 percent by weight.

Claim 13

The article as defined in claim 1 in which the sulfur content of said third layer is less than the sulfur content of said second layer.

Claim 14

The article as defined in claim 1 in which the average sulfur content of said second layer is about 0.1 to about 0.2 percent by weight.

Claim 15

The article as defined in claim 2 in which said chromium plate is of a thickness of about 0.002 to about 0.05 mil.

Claim 16

The article as defined in claim 2 in which the thickness of said chromium plate is about 0.01 to about 0.02 mil.

Claim 17

The article as defined in claim 3 in which said nickel-containing layer on said third layer is of a thickness of about 0.005 to about 0.2 mil.

Claim 18

The article as defined in claim 3 in which the thickness of said nickel-containing layer on said third layer is about 0.05 to about 0.1 mil.

Claim 19

A composite electroplated article comprising a body having an electrically conductive surface, an adherent first layer on said surface of a thickness of about 0.2 to about 2 mils comprising a nickel-iron alloy having an average iron content of about 15 to about 50 percent by weight, an adherent second layer on said first layer of a thickness of about 0.005 to about 0.2 mil comprising a nickel-containing plate having an average sulfur content of about 0.02 to about 0.5 percent by weight, and an adherent third layer on said second layer of a thickness of about 0.2 to about 2 mils comprising a nickel-iron alloy having an average iron content less than that of said first layer and ranging from about 5 to about 19 percent by weight.

Claim 20

A composite electroplated article comprising a body having an electrically conductive surface, an adherent first layer on said surface of a thickness of about 0.2 to about 2 mils comprising a nickel-iron alloy having an average iron content of about 15 to about 50 percent by weight, an adherent second layer on said first layer of a thickness of about 0.005 to about 0.2 mil comprising a nickel-containing plate having an average sulfur content of about 0.02 to about 0.5 percent by weight, and an adherent third layer on said second layer of a thickness of about 0.2 to about 2 mils comprising a nickel-iron alloy having an average iron content less than that of said first layer and ranging from about 5 to about 19 percent by weight.

Claim 21

A composite electroplated article comprising a body having an electrically conductive surface, an adherent first layer on said surface of a thickness of about 0.5 to about 1 mil comprising a nickel-iron alloy having an average iron content of about 25 to about 35 percent by weight, an adherent second layer on said first layer of a thickness of about 0.05 to about 0.1 mil comprising a nickel-containing plate having an average sulfur content of about 0.1 to about 0.2 percent by weight, and an adherent third layer on said second layer of a thickness of about 0.3 to about 1 mil comprising a nickel-iron alloy having an average iron content of about 10 to about 14 percent by weight.

Claim 22

A composite electroplated article comprising a body having an electrically conductive surface, an adherent first layer on said surface of a thickness of about 0.5 to about 1 mil comprising a nickel-iron alloy having an average iron content of about 25 to about 35 percent by weight, an adherent second layer on said first layer of a thickness of about 0.05 to about 0.1 mil comprising a nickel-containing plate having an average sulfur content of about 0.1 to about 0.2 percent by weight, and an adherent third layer on said second layer of a thickness of about 0.3 to about 1 mil comprising a nickel-iron alloy having an average iron content of about 10 to about 14 percent by weight.

Claim 23

A composite electroplated article comprising a body having an electrically conductive surface, an adherent first layer on said surface of a thickness of about 0.2 to about 2 mils comprising a nickel-iron alloy having an average iron content of about 15 to about 50 percent by weight, an adherent second layer on said first layer of a thickness of about 0.005 to about 0.2 mil comprising a nickel-containing plate having an average sulfur content of about 0.02 to about 0.5 percent by weight, an adherent third layer on said second layer of a thickness of about 0.2 to about 2 mils comprising a nickel-iron alloy having an average iron content less than that of said first layer and ranging from about 5 to about 19 percent by weight, an adherent fourth layer on said third layer comprising a nickel-containing plate of a thickness of about 0.005 to about 0.2 mil, and an adherent fifth outer chromium layer on said fourth layer of a thickness of about 0.002 to about 0.05 mil.

Claim 24

A composite electroplated article comprising a body having an electrically conductive surface, an adherent first layer on said surface of a thickness of about 0.2 to about 2 mils comprising a nickel-iron alloy having an average iron content of about 15 to about 50 percent by weight, an adherent second layer on said first layer of a thickness of about 0.005 to about 0.2 mil comprising a nickel-containing plate having an average sulfur content of about 0.02 to about 0.5 percent by weight, an adherent third layer on said second layer of a thickness of about 0.2 to about 2 mils comprising a nickel-iron alloy having an average iron content less than that of said first layer and ranging from about 5 to about 19 percent by weight, an adherent fourth layer on said third layer comprising a nickel-containing plate of a thickness of about 0.005 to about 0.2 mil, and an adherent fifth outer chromium layer on said fourth layer of a thickness of about 0.002 to about 0.05 mil.

Claim 25

A process for making a composite electroplated article comprising the steps of providing a body with an electrically conductive surface, electrodepositing an adherent first layer on said surface comprising a nickel-iron alloy having an average iron content of about 15 to 50 percent by weight, electrodepositing an adherent second layer on said first layer comprising a nickel-containing plate having an average sulfur content of about 0.02 to about 0.5 percent by weight, and electrodepositing an adherent third layer on said second layer comprising a nickel-iron alloy having an average iron content less than that of said first layer and ranging from about 5 to about 19 percent by weight.

Claim 26

A process for making a composite electroplated article comprising the steps of providing a body with an electrically conductive surface, electrodepositing an adherent first layer on said surface comprising a nickel-iron alloy having an average iron content of about 15 to 50 percent by weight, electrodepositing an adherent second layer on said first layer comprising a nickel-containing plate having an average sulfur content of about 0.02 to about 0.5 percent by weight, and electrodepositing an adherent third layer on said second layer comprising a nickel-iron alloy having an average iron content less than that of said first layer and ranging from about 5 to about 19 percent by weight.

Claim 27

The process as defined in claim 21 including the further step of electrodepositing an adherent chromium plate on said third layer.

Claim 28

The process as defined in claim 21 including the further steps of electrodepositing an adherent fourth layer on said third layer comprising a nickel-containing plate and thereafter electrodepositing an adherent outer chromium plate on said fourth layer.

Claim 29

The process as defined in claim 23 in which said step of electrodepositing said fourth layer is performed to induce micro-discontinuities in said outer chromium plate.

Claim 30

The process as defined in claim 21 in which the steps of electrodepositing said first, second and third layers is performed to provide a first layer of a thickness of about 0.2 to about 2 mils, a second layer of a thickness of about 0.005 to about 0.2 mils and a third layer of a thickness of about 0.2 to about 2 mils.

Claim 31

The process as defined in claim 21 in which the steps of electrodepositing said first, second and third layer is performed to provide a first layer of a thickness of about 0.5 to about 1 mil, a second layer of a thickness of about 0.05 to about 0.1 mil and a third layer of a thickness of about 0.3 to about 1 mil.

Claim 32

The process as defined in claim 21 in which the steps of electrodepositing said first and third layer are performed to provide a third layer having an average iron content of at least about 2 percent less than the iron content of said first layer.

Claim 33

The process as defined in claim 21 in which the steps of electrodepositing said first and third layers are performed to provide an average iron content in said third layer at least 5 percent less than the iron content of said first layer.

Claim 34

The process as defined in claim 21 in which the steps of electrodepositing said first and third layer is performed to provide an average iron content in said third layer of about 50 percent less than the average iron content of said first layer.

Claim 35

The process as defined in claim 21 in which the steps of electrodepositing said first and third layer are performed to provide an average iron content in said first layer of about 25 to about 35 percent and an average iron content in said third layer of about 10 to about 14 percent by weight.

Claim 36

The process as defined in claim 21 in which the steps of electrodepositing said first and third layer are performed to provide an average sulfur content in said first and third layer of about 0.01 to about 0.1 percent by weight.

Claim 37

The process as defined in claim 21 in which the step of electrodepositing said third layer is performed to provide an average sulfur content in said third layer less than the average sulfur content in said second layer.

Claim 38

The process as defined in claim 21 in which the step of electrodepositing said second layer is performed to provide an average sulfur content in said second layer of about 0.1 to about 0.2 percent by weight.

Claim 39

The method as defined in claim 22 in which the step of electrodepositing said outer chromium plate is performed to provide a thickness of about 0.002 to about 0.05 mil.

Claim 40

The process as defined in claim 21 in which the step of electrodepositing said outer chromium plate is performed to provide a thickness of about 0.01 to about 0.02 mil.

Claim 41

The process as defined in claim 23 in which the step of electrodepositing said fourth layer is controlled to provide a thickness of about 0.005 to about 0.2 mil.

Claim 42

The process as defined in claim 23 in which the step of electrodepositing said fourth layer is performed to provide a thickness of about 0.05 to about 0.1 mil.

Claim 43

The process as defined in claim 22 in which the step of electrodepositing said outer chromium plate is performed to produce micro-discontinuities in said chrome plate.

Claim 44

A process for making a composite electroplated article comprising the steps of providing a body with an electrically conductive surface, electrodepositing an adherent first layer on said surface comprising a nickel-iron alloy having an average iron content of about 15 to about 50 percent by weight, electrodepositing an adherent second layer on said first layer comprising a nickel-containing plate having an average sulfur content of about 0.02 to about 0.5 percent by weight, electrodepositing an adherent third layer on said second layer comprising a nickel-iron alloy having an average iron content less than that of said first layer and ranging from about 5 to about 19 percent by weight, electrodepositing an adherent fourth layer on said third layer comprising a nickel-containing plate of a thickness of about 0.005 to about 0.2 mil in a manner to induce microdiscontinuities in an outer chromium plate, and electrodepositing an outer chromium plate on said fourth layer of a thickness of about 0.002 to about 0.05 mil.

Claim 45

A process for making a composite electroplated article comprising the steps of providing a body with an electrically conductive surface, electrodepositing an adherent first layer on said surface comprising a nickel-iron alloy having an average iron content of about 15 to about 50 percent by weight, electrodepositing an adherent second layer on said first layer comprising a nickel-containing plate having an average sulfur content of about 0.02 to about 0.5 percent by weight, electrodepositing an adherent third layer on said second layer comprising a nickel-iron alloy having an average iron content less than that of said first layer and ranging from about 5 to about 19 percent by weight, electrodepositing an adherent fourth layer on said third layer comprising a nickel-containing plate of a thickness of about 0.005 to about 0.2 mil in a manner to induce microdiscontinuities in an outer chromium plate, and electrodepositing an outer chromium plate on said fourth layer of a thickness of about 0.002 to about 0.05 mil.