Abstract:
Multi-layer composite product, featuring low emissivity in the mid-infrared band (as wavelength range 2,5–5 μm) and far-infrared (as wavelength range 8.0–14.0 μm) bands, as well as low reflexivity in the near-infrared (at a wavelength range of 0.7–2.5 μm) and in the visible (as wavelength range 0.3–0.7 μm) bands, including a base constructed with low-density and/or high thermal-resilience structural materials, covered with optionally doped coating, and where, between the base and the coating, at least one intermediate layer of metals or metal oxides is planned for insertion.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of Invention 
     This invention refers to products intended for the aeronautical industry featuring low infrared emissivity and low visible light reflexivity. 
     2. Description of the Prior Art 
     As it is generally known, with regard to coated products, the coating in question must have a high degree of adhesiveness and must withstand transitory mechanical and thermal stresses, which may cause its detachment. 
     A commonly employed solution relies upon the use of special varnishes containing particles of materials featuring the desired optical characteristics. However, the employment of such varnishes is considered not entirely satisfactory. Such varnishes, in fact, when exposed to their normal operating conditions, tend to rapidly deteriorate and erode, thus, rapidly degrading their properties, so that they have to be frequently reapplied. An example of coating of the above-mentioned type is described in the American patent U.S. Pat. No. 5,472,533. 
     As a result, the aeronautical industry needs to gain access to materials featuring a permanent modification of their surface optical properties. 
     SUMMARY OF INVENTION 
     This invention provides for the satisfaction of this need, supplying, in addition, other advantages, which shall hereafter become apparent. 
     As a matter of fact, this invention is a multi-layer composite product featuring low emissivity, particularly in the mid and far infrared bands, and low reflexivity in the visible and near infrared, while including a base constructed with low-density and/or high thermal-resilience structural materials. These materials are covered with a coating chosen from the group comprising the semiconductor oxides, which may be doped. 
     The invention&#39;s multi-layer composite product is capable of reducing mid- and far-infrared emissivity (between 2.5 and 4 μm and between 8 and 14 μm), by providing an average value lower than 0.4, while maintaining a low reflexivity in the visible band (neutral or grey coloration) and in the near-infrared (between 0.7 and 2.5 μm), by providing an average value lower than 0.3. 
     The low-density structural base material may be chosen from the group comprising Al, Al alloys, Ti, Ti alloys, polymer-matrix composites, carbon-fibre composites. 
     The low-density and high thermal-resilience structural base material may be a carbon-fibre composite, preferably of the C—C and C—SiC type. 
     The high thermal-resilience structural base material may be chosen from the group comprising steels, as well as Nickel and Cobalt super-alloys. 
     The doped oxide superconductors of the coating may be chosen from the group comprising In 2 O 3  doped with Tin, CdIn 2 O 4 , Zn 2 In 2 O 5 , ZnO doped with aluminum, ZnO doped with tin, SnO 2  doped with antimony, SnO 2  doped with fluorine, CdO doped with tin. 
     Between the base and the coating, an intermediate layer, chosen from the group comprising metals such as indium, cadmium, zinc, tin, aluminum, antimony or their alloys, as well as metal oxides such as indium, cadmium, zinc, tin, aluminum, titanium, tungsten which may be doped with elements such as tin, aluminum, antimony and fluorine, may also be inserted as an option. 
     The deposition of the coating and of any optional intermediate layers is obtained with dry deposition techniques, such as Vapour Deposition, Physical Vapour Deposition (PVD), Chemical Vapour Deposition (CVD) and Thermospraying, or by wet deposition, such as Chemical Deposition and Electro-deposition. 
     The main product and process advantage allowed by this invention resides in its ability to allow the deposition of metallic materials featuring the desired optical properties, which are capable of permanently bonding to the intended support. 
     The multi-layer composite product resulting from the invention has a multiplicity of applications. 
     For instance, it may be employed where it is necessary to maintain a reduced heat transfer occurring through radiation, such as that produced by the components of machines, devices and mechanical/electronic equipment, which, during their operating life, are subject to heating. In such cases, a high emissivity in the infrared field may affect devices and equipment adjacent to those subject to heating. 
     The use of these multi-layer composite products is also applicable to situations where it is necessary to prevent, especially in confined spaces, the onset of greenhouse effects, determined by solar or artificial illumination, producing an uncontrolled temperature increase in such spaces. 
     Another area where the invention can be applied is that of components that, during their operating life, are subject to attrition, in particular to air attrition. This occurs on the external surface of vehicles that are rapidly moving in the air and are subject to attrition, as well as to their parts. The localised temperature increase may determine a high wave emission in the infrared band, which may disturb adjacent electric or electronic equipment and/or allow for vehicle detection by monitoring systems and/or missile guidance systems. 
     Within the context of what was previously mentioned, the need to obtain low emissivity levels within the infrared may go with the need to obtain a low reflectivity in the visible and near-infrared bands, for instance in order to avoid having the reflection of natural or artificial external sources contribute to vehicle detection by monitoring systems and/or missile guidance systems. 
     The employment of the composite for the purposes of the invention is particularly suitable for the aircraft surfaces that are most subject to aerodynamic heating, such as the junction ends of the wings and of the control surfaces, the front end of the fuselage, and the air intakes. 
     This invention will be discussed hereinafter with regards to some of its preferred applications, which are provided as examples and are not at all exhaustive, while referring to the following examples and attached drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows a microphotograph of the section obtained for the production of the first prototype of the composite for the purposes of the invention viewed using SEM (Scanning Electron Microscopy). 
         FIG. 2  shows the concentration profile, determined using the GDOES (Glow Discharge Optical Emission Spectroscopy) technique, obtained for the production of the first prototype of the composite for the purposes of the invention. 
         FIG. 3  shows the emissivity in the infrared obtained for the production of the first prototype of the composite for the purposes of the invention. 
         FIG. 4  shows a section microphotograph obtained for the production of the second prototype of the composite for the purposes of the invention viewed using the SEM (Scanning Electron Microscopy). 
         FIG. 5  shows the emissivity in the infrared obtained for the production of the second prototype of the composite for the purposes of the invention. 
         FIG. 6  shows the emissivity in the infrared obtained for the production of the third prototype of the composite for the purposes of the invention. 
         FIG. 7  shows the outcome of the reflectivity measurements taken for the production of the third prototype of the composite for the purposes of the invention. 
         FIG. 8  shows the emissivity in the infrared obtained for the production of the fourth prototype of the composite for the purposes of the invention. 
         FIG. 9  shows the outcome of the reflectivity measurements taken for the production of the fourth prototype of the composite for the purposes of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     EB-PVD is one of the technologies employed to produce this type of coating. This vapour technology employs an electron gun in order to vaporize the materials to be deposited, and allows for the deposition of layers some hundreds of nanometers thick in a few minutes. 
     To obtain differentiated values of spectrum emissivity in the infrared and visible bands and to produce surface layers capable of withstanding their operating stresses (wear and corrosion), thin coatings more than 100 μm thick and well adherent to their substrates or bases were produced using PVD (Physical Vapour Deposition) technology. 
     PVD Evaporation technologies consist of vacuum evaporation processes (10 −5  Pa) of a solid material with subsequent condensation of the substrate vapour to be coated. In those processes where heating occurs by electrical resistance, the material to be evaporated is contained in a refractory metal crucible that is heated up to the evaporation temperature, while letting high amperage currents through. 
     Another production process involves an electronic gun, aimed at evaporating the coating material, and the use of a magnetic field to direct the electron-beam into the crucible. This method allows for the deposition of metals whose vapour tension is relatively low, such as Al, Ti, Pt or W, as well as the deposition of some insulating materials, such as Al 2 O 3  and SiO 2 . The components being produced are rotated inside a vaporising cloud during the process of deposition and are generally vacuum pre-heated. 
     In order to prevent the loss of the support&#39;s mechanical properties, the construction of the product related to this invention involved the resolution of two special issues regarding the aluminum base: coating adhesion and deposition temperature control. 
     The deposition was obtained using EB-PVD, since such technology allows for the production of fills whose thickness amounts to hundreds of nanometers in short spans of time. The coating/support adhesion problems, typical of this technology, were resolved by producing low-thickness fills and using a tin substrate, which was found to be useful to guarantee good adhesion to the support/base, particularly with aluminum. 
     To prevent the loss of the mechanical properties of the aluminum alloys due to the excessive heating of the substrate, rigorous control of the object&#39;s temperature (T&lt;150° C.) was implemented during the process, both during pre-treatment (ion etching) and during deposition. 
     So far we have made a general description of this invention. With the help of the illustrations and examples that follow, we will now provide a more detailed description of the type of construction illustrated, with the aim of better understanding its purposes, features, advantages, and modes of application. 
     EXAMPLES 
     Various products were obtained by employing electronic-gun deposition equipment, operating through Physical Vapour Deposition, which allows for the monitoring of the substrate temperature during pre-treatment and deposition processes. 
     Example 1 
     (Aluminum-Alloy-Based Product, with Zinc Oxide Coating, Doped with Aluminum (AZO) and an Intermediate Layer of Tin). 
     The product was obtained using a procedure that will be described in detail below, by employing the evaporation PVD technology. Such procedure was optimised considering three general conditions:
         Decrease in thickness, with the goal of diminishing the residual stresses;   Deposition of the various layers without opening the deposition chamber;   Process temperature kept well below 150° C. to prevent degradation of the mechanical properties of the base material.       

     The product was obtained using PVD evaporation technology as follows:
         Chemical cleaning of the base material   Ion bombardment   Deposition of three subsequent substrates of tin, zinc and aluminum in sequence, by keeping the chamber at low pressure; an electrical resistance evaporator was used for the zinc, while the tin and aluminum were evaporated using an EB (Electron Beam) electronic gun.       

     Table I shows the process parameters used for the deposition of the product described above. 
     
       
         
               
               
               
               
             
               
               
               
               
               
               
               
             
           
               
                   
                 TABLE I 
               
             
             
               
                   
                   
               
               
                   
                 Ion bombardment 
                 Deposition 
                   
               
             
          
           
               
                   
                   
                   
                 Temper- 
                   
                 Temper- 
                   
               
               
                 Sub- 
                 Coating 
                 Time 
                 ature 
                 Time 
                 ature 
                 EB Power 
               
               
                 strate 
                 material 
                 (min.) 
                 (° C.) 
                 (s) 
                 (° C.) 
                 (Kw) 
               
               
                   
               
               
                 Al 2024 
                 Sn 
                 23 
                 &lt;150 
                 17 
                 &lt;150 
                 53 
               
               
                   
                 Zn 
                   
                   
                 30 
                   
                 Evaporator 
               
               
                   
                 Al 
                   
                   
                 12 
                   
                 58 
               
               
                   
               
             
          
         
       
     
     The attached  FIG. 1  shows a microphotograph of the section of the product, as described in this example and viewed using SEM (Scanning Electron Microscopy). 
     The structure of the zinc intermediate layer, typical of the resistance-induced PVD evaporation coating method, is made of open blades, which are suitable for oxidation, thus facilitating the development of the AZO surface layer. 
     The attached  FIG. 2  shows the concentration profile, determined using the GDOES (Glow Discharge Optical Emission Spectroscopy) technique, of the product being described in this example. 
     The attached  FIG. 3  shows the emissivity in the infrared of the product described in this example: the sample shows an average value lower than 0.4 in the mid-infrared and lower than 0.2 in the far-infrared bands. 
     To determine the optical properties in the visible, product colorimetric measurements were taken. With reference to the various possible criteria to define the colour of an object, we adopted those in regulation ASTM E308-94 “Standard Practice for Computing the Colours of Objects by Using the CIE System”. In such space, the colour is defined by three co-ordinates, L*, a* and b*. 
     The first co-ordinate, L*, is named Clarity Factor and it considers the luminosity of the object: as it increases from 0 to 100 the colour goes from black to white. The other two co-ordinates, ranging from −60 to +60, identify the actual colour of the object and are called Chromatic Co-ordinates. 
     From the calorimetric measurement shown in Table II, it is clear that the product&#39;s colour is light grey. 
     
       
         
               
               
               
             
           
               
                 TABLE II 
               
               
                   
               
               
                 L* 
                 a* 
                 b* 
               
               
                   
               
             
             
               
                 68.4 
                 −2.3 
                 −0.9 
               
               
                   
               
             
          
         
       
     
     Example 2 
     (Aluminum-alloy-based Product, with Zinc Oxide Coating, Doped with Aluminum (AZO)) 
     The product was obtained using a procedure that will be described in details below, employing the evaporation PVD technology. In this example as well, such procedure was optimised considering the three general conditions described in Example 1. 
     The product was obtained using the PVD evaporation technology as follows:
         Chemical cleaning of the base material   Ion bombardment   Deposition of a layer of zinc and aluminum; evaporated by using an electronic gun.       

     Table I shows the process parameters used for the deposition of the product described above, by alternating the beam&#39;s action on the two crucibles containing zinc and aluminum, so that a layer of a 97%-zinc-and-3%-aluminum alloy may be deposited. 
     Table III shows the process parameters used for the deposition of the product described above. 
     
       
         
               
               
               
               
             
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
             
           
               
                   
                 TABLE III 
               
             
             
               
                   
                   
               
               
                   
                 Ion bombardment 
                 Deposition 
                   
               
             
          
           
               
                   
                   
                   
                 Temper- 
                   
                 Temper- 
                   
               
               
                   
                 Coating 
                 Time 
                 ature 
                 Time 
                 ature 
                 EB Power 
               
             
          
           
               
                 Substrate 
                 material 
                 (min.) 
                 (° C.) 
                 (s) 
                 (° C.) 
                 (Kw) 
               
               
                   
               
             
          
           
               
                 Al 2024 
                 Zn + Al 
                 23 
                 &lt;150 
                 12 
                 &lt;150 
                 58 
               
               
                   
               
             
          
         
       
     
     The attached  FIG. 4  shows a microphotograph of the section of the product, as described in this example, viewed using SEM (Scanning Electron Microscopy). 
     The intermediate layer of zinc and aluminum, obtained by using EB-PVD, on the surface of which the AZO surface layer was developed, is evident. 
     The attached  FIG. 5  shows the emissivity in the infrared of the product described in this example: the sample shows an average value lower than 0.2 in the mid- and far-infrared. 
     To determine the optical properties in the visible, product calorimetric measurement were taken, assessing the colour by using the same criterion described in Example 1 above. 
     From the colorimetric measurement shown in Table IV, it is clear that the product&#39;s colour is light grey. 
     
       
         
               
               
               
             
           
               
                 TABLE IV 
               
               
                   
               
               
                 L* 
                 a* 
                 b* 
               
               
                   
               
             
             
               
                 53.4 
                 0.1 
                 −1.8 
               
               
                   
               
             
          
         
       
     
     Example 3 
     (Aluminum-alloy-based Product, with Indium-oxide-based Coating, Doped with Tin (ITO) and Intermediate Layer of Tungsten Oxide) 
     The product was obtained as follows:
         Deposition, by using PVD sputtering, of a Tungsten Oxide layer (WO3);   Deposition, by using PVD sputtering, of an Indium Oxide layer, doped with 10% of Tin (ITO).       

     Table V shows the process parameters used for the deposition of the two layers. 
     The attached  FIG. 6   FIG. 6  shows the emissivity in the infrared of the product shown in this example: the sample shows an average value lower than 0.2 in the mid- and far-infrared. 
     
       
         
               
               
               
               
               
             
               
               
               
               
             
           
               
                   
                 TABLE V 
               
               
                   
                   
               
               
                   
                   
                 Potential 
                 Bias 
                 Deposition Time 
               
               
                   
                 Material 
                 (V) 
                 (V) 
                 (minutes) 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                 WO 3   
                 600 
                 5.5 
                 45 
               
               
                 ITO 
                 550 
                 5.5 
                 20 
               
               
                   
               
             
          
         
       
     
     To determine the optical properties in the visible and near-infrared, reflexivity measurements were taken on the product, the results of which are shown in the attached  FIG. 7 : the sample shows an average value lower than 0.2 in the visible and lower than 0.3 in the near infrared. 
     Example 4 
     (Aluminum-alloy-based Product, with Indium-oxide-based Coating Doped with Tin (ITO) and Intermediate Layer of Aluminum Oxide) 
     The product was obtained as follows:
         Construction, using anodic oxidation, of an aluminum-oxide layer;   Deposition, by using PVD sputtering, of an indium oxide layer doped with 10% of tin (ITO).       

     The anodic oxidation treatment consists of inducing, using galvanisation, a layer of porous aluminum; the component is subsequently immersed in a bath containing substances that react with the oxide and form dark-coloured compounds. In this example, inorganic substances have been employed as the colouring agent. 
     The parameters employed for the deposition of the ITO layer are the same as shown in Table V of Example 3. 
     The attached  FIG. 8  shows the emissivity in the infrared of the product described in this example: the sample shows an average value lower than 0.4 in the mid- and far-infrared. 
     To determine the optical properties in the visible and near-infrared bands, the product was subjected to reflexivity measurements, the results of which are shown in the attached  FIG. 9 : the sample shows an average value lower than 0.2 in the visible and lower than 0.3 in the near-infrared bands. 
     Persons skilled in the art, in order to satisfy further and specific needs, may introduce several additional modifications and variables of the above-described multi-layer composite product featuring low emissivity in the infrared and high emissivity in the visible, as well as modifications and variables of the related production procedures.