Method for making metallided foils

Claim 2

A process for applying an interdiffused metal coating to a conductive substrate selected from the group of boron, molybdenum, silicon, tungsten, niobium, graphite, technetium, rhenium, the platinum group metals, electrically conductive ceramics and mixtures thereof comprising the steps of: applying a base metal coating to the substrate; applying a second metal to the coated substrate using a measurable quantity of electrical current at a rate temperature to produce interdiffusion between the base metal and the second metal but not between the substrate and the metals.

Claim 7

The method of claim 3 wherein the temperature exceeds 454° C. and the current density at coated surface portions of the coated substrate does not exceed 100 milliamperes per square centimeter.

Claim 9

The method of claim 5 wherein electrodeposition is conducted in a nonaqueous electrolysis bath of alkali metal halide and halide salt of the more active second metal.

Claim 12

The method of claim 7 wherein the temperature exceeds 454° C. and the current density at coated surface portions of the coated substrate does not exceed 100 milliamperes per square centimeter.

Claim 14

The method of claim 9 wherein electrodeposition is conducted in a nonaqueous electrolysis bath of alkali metal halide and halide salt of the more active second metal.

Claim 15

A process for producing a metal alloy foil comprising the steps of: applying a coating of a metal to an electrically conductive substrate; immersing the substrate in an electrolysis bath comprising at least one molten alkali metal halide and a halide salt of a second coating metal; providing an electrode including the second coating metal; maintaining the bath at a temperature of greater than about 454° C.; impressing an electrical current between the substrate and the second metal electrode whereby ions of the second metal become detached from the second metal electrode and deposit upon the substrate, the electrical current being of a magnitude to encourage substantial interdiffusion between the first and second metals in coating the substrate; and stripping the resulting interdiffused coating from the substrate.

Claim 16

A process for producing a metal alloy foil comprising the steps of: applying a coating of a metal to an electrically conductive substrate; immersing the substrate in an electrolysis bath comprising at least one molten alkali metal halide and a halide salt of a second coating metal; providing an electrode including the second coating metal; maintaining the bath at a temperature of greater than about 454° C.; impressing an electrical current between the substrate and the second metal electrode whereby ions of the second metal become detached from the second metal electrode and deposit upon the substrate, the electrical current being of a magnitude to encourage substantial interdiffusion between the first and second metals in coating the substrate; and stripping the resulting interdiffused coating from the substrate.

Claim 17

The method of claim 11 wherein electrical current density at the substrate does not exceed 100 milliamperes per square centimeter.

Claim 18

The process of claim 11 wherein the bath is essentially free of oxygen and metal oxides.

Claim 19

A process for making an alloy metal foil of a first metal and a more active metal comprising the steps of: coating a conductive substrate with the first metal; immersing the coated substrate in a nonaqueous electrolysis bath including at least one alkali metal halide and a halide salt of the more active metal, the bath being at a temperature greater than about 454° C. and the bath being essentially free of oxygen and metal oxides; impressing an electrical current of not greater than 100 milliamperes per square centimeter of coated substrate surface between the coated substrate and an electrode, the electrode including the more active metal and being immersed in the electrolysis bath; maintaining the electrical current at a level to cause ions of the more active metal to deposit upon the conductive substrate and substantially interdiffused with the first metal coating until a desired stoichiometric quantity of the more active metal has been deposited; and stripping the resulting alloy metal foil from the substrate.

Claim 20

A process for making an alloy metal foil of a first metal and a more active metal comprising the steps of: coating a conductive substrate with the first metal; immersing the coated substrate in a nonaqueous electrolysis bath including at least one alkali metal halide and a halide salt of the more active metal, the bath being at a temperature greater than about 454° C. and the bath being essentially free of oxygen and metal oxides; impressing an electrical current of not greater than 100 milliamperes per square centimeter of coated substrate surface between the coated substrate and an electrode, the electrode including the more active metal and being immersed in the electrolysis bath; maintaining the electrical current at a level to cause ions of the more active metal to deposit upon the conductive substrate and substantially interdiffused with the first metal coating until a desired stoichiometric quantity of the more active metal has been deposited; and stripping the resulting alloy metal foil from the substrate.