Patent ID: 9103022
Filing Date: 2015-08-11
Classification: C22C,C23C,Y10T

Abstract:
1. A method of forming an amorphous aluminum alloy coating comprising: providing a vacuum chamber; providing a substrate for coating, wherein said substrate is an aluminum alloy comprising aluminum present at levels in the range of 75 atomic percent to 99 atomic percent and one or more of the following elements: Cu, Cr, Fe, Mg, Mn, Si, Ti, and Zn, present in the range of 1 atomic percent to 25 atomic percent, and said alloy exhibits a density in the range of 2.75 grams per cubic centimeter to 3.0 grams per cubic centimeter and a coefficient of thermal expansion in the range of 24 μm/m−° C. to 30 μm/m−° C.; providing a target material comprising aluminum and one or more alloying elements; providing an inert process gas; applying a bias voltage to said substrate; applying 1 to 10 kW of power at a negative bias to said target and forming plasma with said inert process gas; ejecting particles from said target and depositing an amorphous aluminum alloy coating wherein at least 50% of said alloy is amorphous and includes nanocrystalline domains of 100 nanometers or less as deposited, and said amorphous aluminum alloy coating consists of aluminum present in the range of 75 to 85 atomic percent, cerium present in the range of 5 to 15 atomic percent and cobalt present in the range of 5 to 15 atomic percent, wherein said coating indicates a ΔEpassive of greater than 0.250 Vsce.