Process for providing metallic articles and the like with wear-resistant coatings, and improved coated metallic articles and the like

Claim 2

A metallic article having a wear-improved surface to which is adhered a thin fractional mil nickel-boron porous coating having voids filled with, and a surface coated by, a hardened molten mixture of a metal softer than the porous coating and a low friction coefficient dry lubricant material, the porosity of the nickel-boron coating being of the order from about 20% to 50% surface voids.

Claim 3

A metallic article as claimed in claim 1 and in which the soft metal is of indium and the dry lubricant material is of polytetrafluoroethylene.

Claim 4

A metallic article as claimed in claim 1 and in which the said coated surface has been cryogenically cooled upon the article.

Claim 5

A metallic article as claimed in claim 1 and in which the soft-metal-dry lubricant coating is of thickness less that of the nickel-boron coating.

Claim 6

A metallic article as claimed in claim 4 and in which said nickel boron coating is of thickness of the order of about 0.07 mils, and said soft metal dry lubricant coating is of thickness of the order of from about 0.01 to 0.04 mils.

Claim 7

A metallic article having a wear-improved surface to which is adhered a thin fractional mil nickel-boron porous coating with voids filled with, and a surface coated by, metal that is softer than the porous coating and that has been deposited and melted thereupon, the porosity of the nickel-boron coating being of the order from about 20% to 50% surface voids.

Claim 8

A metallic article having a wear-improved surface to which is adhered a thin fractional mil nickel-boron porous coating with voids filled with, and a surface coated by, metal that is softer than the porous coating and that has been deposited and melted thereupon, the porosity of the nickel-boron coating being of the order from about 20% to 50% surface voids.

Claim 9

A metallic article as claimed in claim 6 and in which the soft metal deposit is of thickness less than the said coating.

Claim 10

A metallic article having a wear-improved surface formed by immersing a prepared article surface in a catalytic nucleation plating bath containing a nickel salt and borohydride reducing agent, the plating having been adjusted to effect a nickel-boron coating at a deposition rate of the order of about half to a few mils per hour, which would normally result in a strong adhering, hard, nucleated, amorphous, low porosity coating of the order of a few mils thickness after at least an hour or more of deposition; the plating nucleation having been discontinued at a fraction of such hour where the coating has adhered to the article surface as a coating thickness of the order of a small fraction of a mil, and still retains voids that provide a porosity of the order of about 20% to 50% more or less to provide a porous surface; the surface then having been heat-treated; a thin deposit of metal softer than the coating then having been electrodeposited upon the porous surface; a low friction coefficient dry lubricant material then having been applied to the porous surface; the surface then having been further heat-treated to diffuse the soft metal therethrough and to cause the dry lubricant material and soft metal to flow in molten combined form within the voids of and over the total area of the porous surface so as to merge therewith; and the article then having been cooled.

Claim 11

A metallic article having a wear-improved surface formed by immersing a prepared article surface in a catalytic nucleation plating bath containing a nickel salt and borohydride reducing agent, the plating having been adjusted to effect a nickel-boron coating at a deposition rate of the order of about half to a few mils per hour, which would normally result in a strong adhering, hard, nucleated, amorphous, low porosity coating of the order of a few mils thickness after at least an hour or more of deposition; the plating nucleation having been discontinued at a fraction of such hour where the coating has adhered to the article surface as a coating thickness of the order of a small fraction of a mil, and still retains voids that provide a porosity of the order of about 20% to 50% more or less to provide a porous surface; the surface then having been heat-treated; a thin deposit of metal softer than the coating then having been electrodeposited upon the porous surface; a low friction coefficient dry lubricant material then having been applied to the porous surface; the surface then having been further heat-treated to diffuse the soft metal therethrough and to cause the dry lubricant material and soft metal to flow in molten combined form within the voids of and over the total area of the porous surface so as to merge therewith; and the article then having been cooled.

Claim 12

An article in accordance with claim 8, wherein the coating has a thickness not exceeding 0.09 mil, wherein the deposit of metal has a thickness less than that of the coating.

Claim 13

An article in accordance with claim 9, wherein the surface has been cooled by cryogenic cooling before the deposition of the nickel-boron coating in order to relieve stresses for improving the load base of the article.

Claim 14

An article in accordance with claim 9, wherein after the further heat-treating the article has been cryogenically cooled to improve the properties of the combined nickel-boron and softer metal and dry lubricant coating.

Claim 15

An article in accordance with claim 9, wherein the further heat-treating has been effected first at a relatively low temperature to melt and diffuse the softer metal into the porous surface and then at a relatively high temperature sufficient to melt the lubricant material to cause a merging of the softer metal and lubricant material together and with the porous surface.

Claim 16

An article in accordance with claim 12, wherein the softer metal is indium and the lubricant material is polytetrafluoroethylene.

Claim 17

A metallic article having an improved wearing and friction-resistant surface formed by immersing the article surface in a catalytic nucleation plating bath containing a salt selected from nickel and cobalt and a reducing agent selected from borohydride and phosphorous salts, the plating having been controlled to effect a coating at a deposition rate of the order of about half to a few mils per hour and having been discontinued at a fraction of an hour when the coating has adhered to the article surface as a coating of thickness not exceeding 0.09 mil and still retains voids that provide a porosity of the order of 20% to 50% more or less to provide a porous surface; the surface then having been heat-treated; a deposit of metal substantially softer than the coating and of thickness less than the coating then having been electrodeposited upon the porous surface; a dry lubricant material then having been applied to the porous surface; the surface then having been further heat-treated to diffuse the softer metal therethrough and to cause the lubricant material and softer metal to flow in molten combined form within the voids of and over the total area of the porous surface so as to merge therewith; and the article then having been cooled.

Claim 18

A metallic article having an improved wearing and friction-resistant surface formed by immersing the article surface in a catalytic nucleation plating bath containing a salt selected from nickel and cobalt and a reducing agent selected from borohydride and phosphorous salts, the plating having been controlled to effect a coating at a deposition rate of the order of about half to a few mils per hour and having been discontinued at a fraction of an hour when the coating has adhered to the article surface as a coating of thickness not exceeding 0.09 mil and still retains voids that provide a porosity of the order of 20% to 50% more or less to provide a porous surface; the surface then having been heat-treated; a deposit of metal substantially softer than the coating and of thickness less than the coating then having been electrodeposited upon the porous surface; a dry lubricant material then having been applied to the porous surface; the surface then having been further heat-treated to diffuse the softer metal therethrough and to cause the lubricant material and softer metal to flow in molten combined form within the voids of and over the total area of the porous surface so as to merge therewith; and the article then having been cooled.

Claim 19

A metallic article having an improved wearing and fricion-resistant surface formed by immersing the article surface in a catalytic nucleation plating bath containing a nickel salt and a borohydride reducing agent, the plating having been controlled to effect a nickel-boron coating at a deposition rate of the order of about half to a few mils per hour and having been discontinued at a fraction of an hour where the coating has adhered to the article surface as a coating surface not exceeding 0.09 mil, and still retains voids that provide a porosity of the order of about 20% to 50% more or less to provide a porous surface; the surface then having been heat treated; and a metal that is substantially softer than the coating and of thickness less than that of the coating then having been electrodeposited upon the porous surface; the porous surface then having been further heat-treated to diffuse the softer metal therethrough and to cause the softer metal to merge therewith; and the article then having been cooled.

Claim 20

A metallic article having an improved wearing and fricion-resistant surface formed by immersing the article surface in a catalytic nucleation plating bath containing a nickel salt and a borohydride reducing agent, the plating having been controlled to effect a nickel-boron coating at a deposition rate of the order of about half to a few mils per hour and having been discontinued at a fraction of an hour where the coating has adhered to the article surface as a coating surface not exceeding 0.09 mil, and still retains voids that provide a porosity of the order of about 20% to 50% more or less to provide a porous surface; the surface then having been heat treated; and a metal that is substantially softer than the coating and of thickness less than that of the coating then having been electrodeposited upon the porous surface; the porous surface then having been further heat-treated to diffuse the softer metal therethrough and to cause the softer metal to merge therewith; and the article then having been cooled.

Claim 21

A metallic article having an improved wearing and friction-resistant surface formed by immersing the article surface in a catalytic nucleation plating bath containing a salt selected from nickel and cobalt and a reducing agent selected from borohydride and phosphorous, the plating having been controlled to effect a coatng at a deposition rate of the order of about a half to a few mils per hour and having been discontinued at a fraction of an hour where the coating has adhered to the article surface as a coating thickness not exceeding 0.09 mil and still retains voids that provide a porosity of the order of 20% to 50% more or less to provide a porous surface; the surface then having been heat-treated; and a metal that is substantially softer than the coating and of a thickness less than that of the coating then having been electrodeposited upon the porous surface; the porous surface then having been further heat-treated to diffuse the softer metal therethrough and to cause the softer metal to merge therewith; and the article then having been cooled.

Claim 22

A metallic article having an improved wearing and friction-resistant surface formed by immersing the article surface in a catalytic nucleation plating bath containing a salt selected from nickel and cobalt and a reducing agent selected from borohydride and phosphorous, the plating having been controlled to effect a coatng at a deposition rate of the order of about a half to a few mils per hour and having been discontinued at a fraction of an hour where the coating has adhered to the article surface as a coating thickness not exceeding 0.09 mil and still retains voids that provide a porosity of the order of 20% to 50% more or less to provide a porous surface; the surface then having been heat-treated; and a metal that is substantially softer than the coating and of a thickness less than that of the coating then having been electrodeposited upon the porous surface; the porous surface then having been further heat-treated to diffuse the softer metal therethrough and to cause the softer metal to merge therewith; and the article then having been cooled.