COMPOSITE MATERIAL AND THE PRODUCTION THEREOF

Abstract: A composite gold-coloured coinage material comprises a base of or faced with nickel or a corrosion-resistant nickel alloy, the faces being coated with a deposit of gold at least 0.1 µm thick, the deposit being metallurgically bonded to the faces and having nickel from the faces diffused through it to increase its hardness without impairing its gold colour.

Description: Composite material and the production thereof This invention relates to coinage material, that is to say coins, tokens, coin or token blanks or sheet or strip of coinage thickness for use in making coins or tokens by the conventional steps of stamping out blanks, sizing, coining, rimming and milling. Since the time of the Lydians gold has been used for coins of high face value. Nowadays, however, the intrinsic value of gold is so high that gold coins are no longer circulated widely, but exist essentially as collectors' or investment items. Moreover gold would be too soft for the severe conditions to which coins are now subjected in everyday use. In particular their increasing use in coin-operated machines subjects current coins to a high degree of wear. The greater need for high resistance to both wear and corrosion has also led to changes in the silver coloured alloys now used for higher-value coins. Thus the Canadian 25° piece was changed from a silver-copper alloy to pure nickel in 1968. In 1965 the United States 25d piece was changed from a90% silver-lO% copper alloy to a composite structure with 75% Cu-25% Ni face layers sandwiching a pure copper core. Other countries have switched to copper based coinage containing Cu plus Al or Zn or Ni or a combination of the latter elements. Actual studies of the wear of coinage alloys as a function of the number of years in service are relatively few, but the wear rates for the Ag-Cu, Cu-Ni and and Ni coins are well established and are shown in Table 1. TABLE 1 Historical Wear Data Wt. Average Wbar Rate Year Coin Material (g) / Current U.S. sic 75% Cu-25% Ni 5.0 4 Pre-1965 U.S. 25 Ag-Cu* 6.25 7 Pre-1968 Can. 25° Ag-Cu* 5.85 6 CanBnt Can. 5° Ni* 4.55 0.9 * Canada's New Nickel Coins, reprinted from Canadian Mining Journal, December, 1968. These results show that pure nickel is much more resistant to wear than the Cu-Ni or Ag-Cu alloys. It is also superior to these alloys in corrosion properties, the next best of the present coinage alloys being 75% Cu-25% Ni cupronickel. Nickel maintains its bright appearance for longer than its normal service life of 20 to 40 years. Thus, for a silver-coloured coinage material pure nickel is by far the best. It also possesses unique magnetic properties between those of iron and nonmagnetic alloys which allow it to be easily discriminated in either mechanical or electrical coin-operated machines. The increasing use of coin-operated vending machines for more expensive articles, together with inflation and the high cost of replacement of paper money, is leading to a demand for coins of higher face value. Larger coins would be inconvenient to carry round in the pocket, but the use of sizes between those of existing coins makes discrimination by the public difficult. It is our object in the present invention to provide a coinage material that combines the gold colour traditionally associated with high value with the wear and corrosion resistance required by present-day conditions of use and exhibited by the best of the silver-coloured coinage materials. Known gold-coloured alloys do not meet these requirements. Coins of brass or bronze alloys would have inadequate wear resistance and would quickly tarnish in service. To change the silver colour of cupronickel to gold the nickel content must be reduced to less than 10%, at which level the alloy tarnishes. Introducing other elements such as Al and Zn into such cupronickel alloys has yielded golden-coloured alloys of only marginally improved tarnish resistance, none being as good as 75% Cu-25% Ni cupronickel, and all being very inferior to pure nickel. According to the invention a composite coinage material comprises a base of which at least the faces are of nickel or a corrosion-resistant nickel alloy and are coated with a deposit of gold at least 0.1 Fm thick, the deposit being metallurgically bonded to the faces and having diffused through it an amount of nickel sufficient to increase its hardness without significantly impairing its gold colour. Such a material may be made by electrodepositing a coating of gold at least 0.1 ssm thick on the faces and heating the coating to interdiffuse the gold and nickel from the base to form a metallurgical bond between the base and the coating and to diffuse the desired amount of nickel through the gold coating. The gold coating may be up to 1.5 m or even 2.5 Am thick. We surprisingly find that coins of such material, particularly those in which the base is of substantially pure nickel and the coating is of gold alloyed only with nickel, can retain their 9old colour on the coin faces in accelerated wear tests corresponding to many years expected normal use. It is of course well known to electrodeposit gold on to a substrate and to form a bond with the substrate by annealing. So far as we are aware, however, none of the disclosures of this process contemplates or suggests that the composite material of the present invention might be useful as a coinage material. Ornamental gold plating of United States coins without inter-diffusion is disclosed in U.S. specification No. 3 834 879 as part of a procedure for differential plating of the pictorial material on the coins, but the resulting plated coins are only for exhibition and not for circulation. The invention will now be described in more detail with reference to the accompanying drawing, which is a graph in which wear of coins of three materials (weight loss in mg) in an accelerated wear test is plotted against time (days). The base of the composite material of the invention is advantageously substantially pure nickel, but can be a high nickel alloy, i.e. containing greater than about 50% nickel, which has corrosion resistance and workability substantially equivalent to that of pure nickel. Corrosion-resistant nickel alloys containing less than 50% nickel, e.g. 75% Cu, 25% Ni, may be used, but are less preferable. Generally speaking, the base of a coin or token structure is monolithic, i.e. made wholly of a single material. However, if desired, the base can be a composite or a sandwich structure provided the surfaces are nickel. In physical form, the base of the composite material is of coin thickness, i.e. up to about 0.6 cm, but can be of any desired width and length. For example, the base can be sheet or strip out of which coin or token blanks can be stamped. Alternatively, the base can be a coin or token blank stamped from a sheet of nickel, or any intermediate form of the coin or token. Specifically, the base can be a blank which has been sized or sized and coined, or sized, coined and rimmed or sized, coined, rimmed and milled. It will be appreciated that gold plating done prior to rimming and milling will result in coins having an edge with the appearance of nickel, but that in any event the front and rear of the coin or token will have a gold colour. The gold is advantageously electrodeposited on the surface of the base as pure (24 carat) gold from an electroplating bath using conditions applicable to obtaining a pure electrodeposit. However, the gold need not be 100% pure: for the purposes of this invention, the term "gold" includes not only pure gold but also yellow alloys and reddish yellow alloys which may contain silver, copper, nickel, a platinum-group metal and combinations thereof. Gold containing up to about 8% to 10% by weight nickel will retain its gold colour equivalent to the colour of 14 carat to 18 carat goldsilver-copper alloy. The gold coating is advantageously electrodeposited from a cyanide type bath. Such baths are usually of proprietary composition. However, the general types of cyanide baths and conditions of operation are set forth in standard reference sources such as Electroplating Engineering Handbook (3 ed.) A. Kenneth Graham, Van Nostrand Reinhold Company (C) 1971 page 242 and in References 1, 2, 29, 30, 31, 32 and 33 listed on page 255 of that work. It is also within the contemplation of the present invention to deposit gold layers of the requisite thickness by means other than electroplating provided, of course, that the quality of the adhesion of the gold layer to the nickel is at least equivalent to that provided by electroplating. As those skilled in the art are aware, the quality of adhesion of an electroplate depends to a large extent on the care taken in surface preparation and cleaning of the base to be plated. In this regard Chapter 3 of the aforecited Electroplating Engineering Handbook,entitled Metal Surface Preparation and Cleaning,is recommended to those desiring to practice the present invention. In producing the composite material of the present invention, the annealing step to achieve the metallurgical bond between gold and nickel and to harden the gold is an important feature. Annealing can be carried out any time after deposition of the gold layer, either before or after working or mechanical operation on the composite material. The conditions of temperature and time of annealing are selected so that an interdiffused layer of gold and nickel is achieved without loss of the desired surface colour. For example, with a pure nickel base and a pure gold deposit averaging 0.3 gm thick, effective annealing in hydrogen at 4500C may be achieved in a short time, e.g. in the range of about 2 to 5 minutes. This annealing time has been determined as residence time in a 5 cm tube furnace under laboratory conditions. Those skilled in the art will appreciate that commercial scale furnacing may vary in temperature and time. Nickel has a significant whitening effect on gold. After approximately 6 minutes of annealing under those specified laboratory conditions, the whitening effect of nickel predominates and the golden colour is lost. Annealing under the same conditions for less than two minutes is insufficient to produce the required metallurgical bond. While this example of annealing teaches an effective annealing procedure operable in the context of the present invention, variations are obviously possible. For example annealing can be conducted at lower temperatures, e.g. down to about 3500C for longer times. Hydrogen can be replaced as an annealing atmosphere by any atmosphere, e.g. cracked ammonia or argon, which will prevent oxidation of the nickel. In addition, if alloy gold is used as the layer, less nickel diffusion can be tolerated and therefore annealing should be carried out at temperatures lower than 4500C and for times less than those employed for pure gold. Still further, if gold is employed in thicker layers, e.g. from 0.5 to 1.0 tim, somewhat greater times or higher temperatures should be employed in annealing in order to permit diffusion of some nickel right through the gold layer in order to induce increased hardness throughout. Conversely, extremely thin gold layers, e.g. about 0.1 tim, must be annealed for very short times in order to retain the visual yellow effect of the gold. Annealing time is also dependent upon the thickness of the nickel-containing base, generally longer times being necessary with thicker bases. The annealing time also depends on the type of heating equipment used. For example, with high frequency induction skin heating shorter times can be used, because there is no need to allow time for the entire base to come to annealing temperature. In general, annealing can be carried out at temperatures of about 350 to about 6500C for about thirty minutes to about a few seconds. Some examples will now be given. EXAMPLE 1 A mint Canadian 25 pure nickel coin was cleaned in a mild acidic solution and plated at 600C at 5 mA/cm2 for 1-2 minutes from a standard cyanide-type Au plating bath obtained from Johnson Matthey and Mallory Ltd. under the trademark "Orosene 999 24 KT bright gold". The weight of the Au plated was 6 mg and the apparent calculated thickness of the Au layer was 0.3 tim. This coin was subsequently annealed at 4500C for 3 to 4 minutes in pure hydrogen, after which it was gold in colour, lighter than the colour of 24 carat gold. The following coins were dipped into a 5 wt.% NaC1 solution which had been adjusted to pH 4 with nitric acid once per day for four days and allowed to air dry at room temperature the balance of the day. 1. Pure Ni Canadian 25°. 2. A U.S. 25 piece having outer faces of 75% Cu-25% Ni and a copper core. 3. A gold coated nickel coin, with the gold coating prepared according to the procedure detailed above. 4. A 1983 British Pound containing 75% Cu-18% Zn - 7%Ni. 5. A gold coated 75% Cu-25% Zn coin, with the gold coating prepared following the same procedure as 3. The surfaces of the pure Ni coin (1) and the new gold-on-Ni coin (3) were not visibly tarnished. The U.S cupronickel 25± (2) lost its metallic lustre but had no visible evidence of a tarnish. The British Pound (4) and the Au-on-brass composite (5) lost their metallic lustre and had objectionable tarnish formed on their surfaces, which is undesirable for high denomination coins. EXAMPLE 2 Eight Canadian 25± pure nickel coins were each plated with 6 mg of Au according to the procedure in Example 1. Four of the coins were subsequently annealed at 4500C for 4 min. in pure hydrogen, while the other four coins were unannealed. The eight coins were then subjected to wear testing. The apparatus for wear testing in this Example and in other Examples herein comprised a ceramic jar mill having internal dimensions of 10.16 cm high and 12.7 cm wide and closely lined with a zippered bag made of metallographic polishing cloth. The coins were introduced into the bag along with an equal weight of metal shot 0.3 to 1.9 cm in diameter made of an alloy containing nominally (in weight percent) 54% nickel, 17% molybdenum, 15% chromium, 5% iron and 4% tungsten, 13 grams of leather strip about 3.8 cm x 0.3 cm x 0.5 cm and 7 grams of cork No. 00 about 0.12 cm in diameter. The leather strip was soaked with synthetic sweat solution (40 g NaCl, 5 g Na2HP04, 4 ml lactic acid, made up to 4 1 with distilled water, the bag was zippered closed, fitted into the ceramic jar mill and then rotated 5 days at 45 rpm (less than critical speed) with the leather being periodically rewet with synthetic sweat solution. The mean weight loss of the annealed coin was 6.8 mg while that for the unannealed coins was 9.0 mg. The annealed samples had a more uniform colour than the unannealed sample. EXAMPLE 3 This example shows the effect of varying the annealing time. Five Canadian pure Ni 25 pieces were plated with 24 carat Au, by the procedure set forth in Example 1. The coins were placed into a 5 cm tube furnace having a H2 atmosphere at 4500C for times ranging from about 1 to about 10 min. The surfaces of the Au plated coins retained their 24 carat appearance up to 3 minutes. After about 4 minutes the colour matched the colour of 18 carat (75% Au, 15% Ag, 10% Cu) gold. After about 6 minutes the gold colour had largely disappeared. EXAMPLE 4 Two samples of the Au coated pure Ni Canadian 25° pieces from Example 2, containing about 6 mg of Au in a layer 0.3 tim thick annealed at 4500C for 4 minutes, together with two U.S. cupronickel 25° pieces and two Canadian pure nickel 25° pieces were tumbled as described in Example 2 in the ceramic mill at 45 rpm in a cloth bag containing cork and leather wetted with synthetic sweat solution and an equal weight of metal. The weight loss of each coin was measured each day. The results ploted in Figure 1 show that the wear rate of the U.S. cupronickel is approximately twice that of pure nickel and that the weight loss of the Au plated and annealed nickel coins was indistinguisable from pure nickel Canadian 25° pieces. It was not anticipated that a coin having roughly 6 mg of gold on nickel would still have a good surface appearance after 20 mg had worn away. Yet even after losing 40 mg of weight the Au coated coin still retained its golden colour, and only on the edges of the coin was Au layer abraded away. EXAMPLE 5 Eight pure Ni Canadian 25 pieces were Au plated using the procedure set forth in Example 1 and annealed at 4500C for 4 minutes. The measured weight of gold electrodeposited was 6 to 8 mg per coin. These coins, together with eight Canadian nickel 25° pieces and eight U.S. cupronickel 25± pieces, were repeatedly placed by hand through a mechanical vending machine coin sorting mechanism. After 8,000 cycles, the U.S. cupronickel coins had lost much of their knurled edge. The edge was quite smooth. After 10,000 cycles the Canadian nickel 25 piece showed some slight rounding of the edge and the Au plated and annealed Canadian 25 piece still retained their original golden colour even on the edges. After 18,000 cycles, the knurled edges on the Canadian 25 piece started to show a slight wear. The Au plated and annealed coins still retained their original golden colour on the coin faces after 18,000 cycles and showed the same slight knurled edge wear as the pure nickel 25 pieces. Some loss of golden colour occurred on the edges after 18,000 cycles. After 18,000 cycles, the total weight of Au on the coins was analysed as 5.25 mg (average) indicating only about a 1.7 mg Au loss and 70% Au retained during the test. Eighteen thousand cycles corresponds to approximately 50 years of wear on a coin at an average use of once per day in a vending machine. EXAMPLE 6 The tumbling test used in Examples 2 and 4 was repeated using the coinage charge of two pure nickel Canadian 25 pieces, two U.S. cupronickel 25° pieces, one Canadian nickel 25° piece plated with 6 mg of Au and annealed as in Example 1 for 4 minutes at 4500C in pure H2, and one Canadian nickel 25° piece plated with 12 mg of Au and annealed to have the same surface colour as the coin having 6 mg of Au after annealing. The tumbling mill was rotated for 1 day at 60 rpm, 3 days at 27 rpm and 1 to 5 days at 45 rpm. The mean weight loss of the coins after this treatment for 5 day and 9 day periods is shown below: 5 day 9 day mg mg U.S. 25° cupronickel 18.9 32.7 Canadian 25° pure Ni 6.2 14.6 6 mg Au on Canadian 25° 6.9 12 mg Au on Canadian 25° 7.4 15.8 The 6 mg and 12 mg Au coins were indistinguishable in appeareance after the test. Both retained their original golden colour even on the edges. EXAMPLE 7 Two samples of pure nickel coin stock electroplated with 0.3 Fm of gold were subjected to Auger analysis to determine the naturevof the gold layer in the unannealed conditions and after annealing as set forth in Example 1. Analysis of the unannealed sample indicated essentially pure gold in the electrodeposited layer with a very sharp boundary to pure nickel of the base. The annealed sample showed essentially a 95% Au-5% Ni composition throughout the gold layer with a somewhat diffuse but relatively sharp boundary to the essentially pure nickel of the base. EXAMPLE 8 The following specimens were dipped once per day for 3-1/2 days into a 5 wt.% NaCl solution which had been adjusted to a pH of 4 with nitric acid, and allowed to air dry at room temperature for the balance of the day. 6. A gold coated 18/8 stainless steel base. 7. A gold coated 75% Cu-25% Ni base. The gold was plated and the composite structure annealed essentially as described in Example 1. The gold plated stainless steel sample (6) showed evidence of tarnish. The gold plated cupronickel sample (7) showed only a slight green oxidation product which was easily wiped off but might remain in crevices in use.

Claims: Claims 1. A composite coinage material comprising a base of which at least the faces are of nickel or a corrosion-resistant nickel alloy, characterised in that the faces are coated with a deposit of gold at least 0.1 tim thick, the deposit being metallurgically bonded to the faces and having diffused through it an amount of nickel sufficient to increase its hardness without significantly impairing its gold colour. 2. A composite coinage material according to claim 1, in which the thickness of the gold deposit does not exceed 1.5 Fm. 3. A composite coinage material according to claim 1 or claim 2 in which the nickel content of the gold deposit does not exceed 8% by weight. 4. A composite coinage material according to any preceding claim in which the base consists of substantially pure nickel and the deposit of gold is alloyed only with nickel. 5. A composite coinage material according to any preceding claim which consists of a coin or token or a rimmed and milled coin or token blank and in which the base is monolithic and the gold coating covers the whole of its surface. 6. A composite coinage material according to any of claims 1 to 4 in which the base is a nickel sheet or strip adapted for coin blanking. 7. A process for producing a coinage material according to claim 1 or claim 4, characterised by the steps of electrodepositing a layer of gold at least 0.1 Fm thick on at least the faces of a nickel or corrosion-resistant nickel alloy base and thereafter interdiffusing the gold and nickel from the base to form a metallurgical bond between the gold deposit and the base and to introduce into the gold deposit an amount of nickel sufficient to increase its hardness but not enough to significantly impair its gold colour. 8. A process according to claim 7 in which the interdiffusion is performed by heating at a temperature of from 350 to 650QC for a period of time such that not more than 10% by weight of nickel is introduced into the gold. 9. A process according to claim 7 or claim 8, in which the interdiffusion is performed in an atmosphere of hydrogen or cracked ammonia. lo. A process according to any of claims 7 to 9, in which gold is electrodeposited on a sheet or strip of nickel or a corrosion-resistant nickel alloy, coins or tokens or coin or token blanks are formed from the coated sheet or strip, and the interdiffusion is then performed.

Inventors: BELL, JAMES ALEXANDER EVERT, CONARD, BRUCE RANDOLPH, HOPE, DOUGLAS ALBERT
Applicants: INCO LIMITED
Application year: 1984
Main classification: B32B15
IPC codes: C25D5, B32B15, A44C21