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Functionally graded alumina-based thin film systems

United States Patent

August 29, 2006
View the Complete Patent at the US Patent & Trademark Office
The present invention provides coating systems that minimize thermal and residual stresses to create a fatigue- and soldering-resistant coating for aluminum die casting dies. The coating systems include at least three layers. The outer layer is an alumina- or boro-carbide-based outer layer that has superior non-wettability characteristics with molten aluminum coupled with oxidation and wear resistance. A functionally-graded intermediate layer or "interlayer" enhances the erosive wear, toughness, and corrosion resistance of the die. A thin adhesion layer of reactive metal is used between the die substrate and the interlayer to increase adhesion of the coating system to the die surface.
Moore; John J. (Evergreen, CO), Zhong; Dalong (Lakewood, CO)
Colorado School of Mines (Golden, CO)
11/ 136,613
May 23, 2005
GOVERNMENT INTEREST This invention was made with Government support under grant No. DE-FC36-00ID13850 awarded by the Department of Energy. The Government has certain rights in this invention.