Patent Grant
7887930
The present invention relates generally to electrodeposited crystalline chromium deposited from trivalent chromium baths, methods for electrodepositing such chromium deposits and articles having such chromium deposits applied thereto.
Chromium electroplating began in the early twentieth or late 19th century and provides a superior functional surface coating with respect to both wear and corrosion resistance. However, in the past, this superior coating, as a functional coating (as opposed to a decorative coating), has only been obtained from hexavalent chromium electroplating baths. Chromium electrodeposited from hexavalent chromium baths is deposited in a crystalline form, which is highly desirable. Amorphous forms of chromium plate are not useful. The chemistry that is used in present technology is based on hexavalent chromium ions, which are considered carcinogenic and toxic. Hexavalent chromium plating operations are subject to strict and severe environmental limitations. While industry has developed many methods of working with hexavalent chromium to reduce the hazards, both industry and academia have for many years searched for a suitable alternative.
Given the importance and superiority of chromium plating, the most obvious alternative source of chromium for chromium plating is trivalent chromium. Trivalent chromium salts are much less hazardous to health and the environment than hexavalent chromium compounds. Many different trivalent chromium electrodeposition baths have been tried and tested over the years. However, none of such trivalent chromium baths have succeeded in producing a reliably consistent chromium deposit that is comparable to that obtained from hexavalent chromium electrodeposition processes.
Hexavalent chromium is very toxic and is subject to regulatory controls that trivalent chromium is not. The most recent OSHA rule for hexavalent chromium exposure was published in 29 CFR Parts 1910, 1915, et al., Occupational Exposure to Hexavalent Chromium; Final Rule. In this Rule, substitution is described as an “ideal (engineering) control measure” and “replacement of a toxic materials with a less hazardous alternative should always be considered” (Federal Register/Vol. 71, No. 39/Tuesday, Feb. 28, 2006/Rules and Regulations pp. 10345). Thus, there are strong government-based mandates to replace hexavalent chromium with another form of chromium. However, until the present invention, no process has been successful in electrodepositing a reliably consistent crystalline chromium deposit from a trivalent or other non-hexavalent chromium electroplating bath.
In general, in the prior art, all of the trivalent chromium electrodeposition processes form an amorphous chromium deposit. While it is possible to anneal the amorphous chromium deposit at about 350 to 370° C., and create thereby a crystalline chromium deposit, the annealing results in the formation of macrocracks, which are undesirable, rendering the chromium deposit essentially useless. Macrocracks are defined as cracks that extend through the entire thickness of the chromium layer, down to the substrate. Since the macrocracks reach the substrate, thus giving ambient materials access to the substrate, the chromium deposit cannot provide its function of corrosion resistance. The macrocracks are believed to arise from the process of crystallization, since the desired body-centered cubic crystalline form has a smaller volume than does the as-deposited amorphous chromium deposit and the resulting stress causes the chromium deposit to crack, forming the macrocracks. By contrast, crystalline chromium deposits from hexavalent electrodeposition processes generally include microcracks that are smaller and extend only a fraction of the distance from the surface of the deposit towards the substrate, and do not extend through the entire thickness of the chromium deposit. There are some instances in which a crack-free chromium deposit from a hexavalent chromium electrolyte can be obtained. The frequency of microcracks in chromium from hexavalent chromium electrolytes, where present, is on the order of 40 or more cracks per centimeter, while the number of macrocracks in amorphous deposits from trivalent chromium electrolytes annealed to form crystalline chromium, where present, is about an order of magnitude less. Even with the much lower frequency, the macrocracks render the trivalent chromium derived crystalline deposit unacceptable for functional use. Functional chromium deposits need to provide both wear resistance and corrosion resistance, and the presence of macrocracks renders the article subject to corrosion, and thus such chromium deposits are unacceptable.
Trivalent chromium electrodeposition processes can successfully deposit a decorative chromium deposit. However, decorative chromium is not functional chromium, and is not capable of providing the benefits of functional chromium.
While it would appear to be a simple matter to apply and adapt the decorative chromium deposit to functional chromium deposits, this has not occurred. Rather, for years the goal has continued to elude the many efforts directed at solving this problem and reaching the goal of a trivalent chromium electrodeposition process that can form a crystalline chromium deposit.
Another reason for seeking a trivalent chromium electrodeposition process is that trivalent chromium based processes theoretically require about half as much electrical energy as a hexavalent process. Using Faraday's law, and assuming the density of chromium to be 7.14 g/cm3 the plating rate of a 25% cathodic efficiency process with 50 A/dm2 applied current density is 56.6 microns per dm2 per hour for a hexavalent chromium plating process. With similar cathodic efficiencies and current density a deposit of chromium from the trivalent state would have twice the thickness in the same time period.
For all these reasons, a long-felt need remains for a functional crystalline-as-deposited chromium deposit, an electrodeposition bath and process capable of forming such a chromium deposit and articles made with such a chromium deposit, in which the chromium deposit is free of macrocracks and is capable of providing functional wear and corrosion resistance characteristics comparable to the functional hard chromium deposit obtained from a hexavalent chromium electrodeposition process. The urgent need for a bath and process capable of providing a crystalline functional chromium deposit from a bath substantially free of hexavalent chromium heretofore has not been satisfied.
The present invention provides a chromium deposit which is crystalline when deposited, and which is deposited from a trivalent chromium solution.
The present invention, although possibly useful for formation of decorative chromium deposits, is primarily directed to functional chromium deposits, and in particular for functional crystalline chromium deposits which heretofore have only been available through hexavalent chromium electrodeposition processes.
The present invention provides a solution to the problem of providing a crystalline functional chromium deposit from a trivalent chromium bath substantially free of hexavalent chromium, but which nevertheless is capable of providing a product with functional characteristics substantially equivalent to those obtained from hexavalent chromium electrodeposits. The invention provides a solution to the problem of replacing hexavalent chromium plating baths.
It should be appreciated that the process steps and structures described below do not form a complete process flow for manufacturing parts containing the functional crystalline chromium deposit of the present invention. The present invention can be practiced in conjunction with fabrication techniques currently used in the art, and only so much of the commonly practiced process steps are included as are necessary for an understanding of the present invention.
As used herein, a decorative chromium deposit is a chromium deposit with a thickness less than one micron, and often less than 0.8 micron, typically applied over an electrodeposited nickel or nickel alloy coating, or over a series of copper and nickel or nickel alloy coatings whose combined thicknesses are in excess of three microns.
As used herein, a functional chromium deposit is a chromium deposit applied to (often directly to) a substrate such as strip steel ECCS (Electrolytically Chromium Coated Steel) where the chromium thickness is generally greater than 0.8 or 1 micron, and is used for industrial, not decorative, applications. Functional chromium deposits are generally applied directly to a substrate. Industrial coatings take advantage of the special properties of chromium, including its hardness, its resistance to heat, wear, corrosion and erosion, and its low coefficient of friction. Even though it has nothing to do with performance, many users want the functional chromium deposits to be decorative in appearance. The thickness of the functional chromium deposit may range from the above-noted 0.8 or 1 micron to 3 microns or much more. In some cases, the functional chromium deposit is applied over a ‘strike plate’ such as nickel or iron plating on the substrate or a ‘duplex’ system in which the nickel, iron or alloy coating has a thickness greater than three microns and the chromium thickness generally is in excess of three microns. Functional chromium plating and deposits are often referred to as “hard” chromium plating and deposits.
Decorative chromium plating baths are concerned with thin chromium deposits over a wide plating range so that articles of irregular shape are completely covered. Functional chromium plating, on the other hand, is designed for thicker deposits on regularly shaped articles, where plating at a higher current efficiency and at higher current densities is important. Previous chromium plating processes employing trivalent chromium ion have generally been suitable for forming only “decorative” finishes. The present invention provides “hard” or functional chromium deposits, but is not so limited, and can be used for decorative chromium finishes. “Hard” or “functional” and “decorative” chromium deposits are known terms of art.
As used herein, when used with reference to, e.g., an electroplating bath or other composition, “substantially free of hexavalent chromium” means that the electroplating bath or other composition so described is free of any intentionally added hexavalent chromium. As will be understood, such a bath or other composition may contain trace amounts of hexavalent chromium present as an impurity in materials added to the bath or composition or as a by-product of electrolytic or chemical processes carried out with bath or composition.
As used herein, the term “preferred orientation” carries the meaning that would be understood by those of skill in the crystallographic arts. Thus, “preferred orientation” is a condition of polycrystalline aggregate in which the crystal orientations are not random, but rather exhibit a tendency for alignment with a specific direction in the bulk material. Thus, a preferred orientation may be, for example, {100}, {110}, {111} and integral multiples thereof, such as (222).
The present invention provides a reliably consistent body centered cubic (BCC) crystalline chromium deposit from a trivalent chromium bath, which bath is substantially free of hexavalent chromium, and in which the chromium deposit is crystalline as deposited, without requiring further treatment to crystallize the chromium deposit. Thus, the present invention provides a solution to the long-standing, previously unsolved problem of obtaining a reliably consistent crystalline chromium deposit from an electroplating bath and a process which are substantially free of hexavalent chromium.
In one embodiment, the crystalline chromium deposit of the present invention is substantially free of macrocracks, using standard test methods. That is, in this embodiment, under standard test methods, substantially no macrocracks are observed when samples of the chromium deposited are examined.
In one embodiment, the crystalline chromium deposit in accordance with the present invention has a cubic lattice parameter of 2.8895+/−0.0025 Angstroms (Å). It is noted that the term “lattice parameter” is also sometimes used as “lattice constant”. For purposes of the present invention, these terms are considered synonymous. It is noted that for body centered cubic crystalline chromium, there is a single lattice parameter, since the unit cell is cubic. This lattice parameter is more properly referred to as a cubic lattice parameter, but herein is referred to simply as the “lattice parameter”. In one embodiment, the crystalline chromium deposit in accordance with the present invention has a lattice parameter of 2.8895 Å+/−0.0020 Å. In another embodiment, the crystalline chromium deposit in accordance with the present invention has a lattice parameter of 2.8895 Å+/−0.0015 Å. In yet another embodiment, the crystalline chromium deposit in accordance with the present invention has a lattice parameter of 2.8895 Å+/−0.0010 Å. Some specific examples are provided herein of crystalline chromium deposits having lattice parameters within these ranges.
Pyrometallurgical, elemental crystalline chromium has a lattice parameter of 2.8839 Å.
Crystalline chromium electrodeposited from a hexavalent chromium bath has a lattice parameter ranging from about 2.8809 Å to about 2.8858 Å.
Annealed electrodeposited trivalent amorphous-as-deposited chromium has a lattice parameter ranging from about 2.8818 Å to about 2.8852 Å, but also has macrocracks.
Thus, the lattice parameter of the chromium deposit in accordance with the present invention is larger than the lattice parameter of other known forms of crystalline chromium. Although not to be bound by theory, it is considered that this difference may be due to the incorporation of heteroatoms, such as sulfur, nitrogen, carbon, oxygen and/or hydrogen in the crystal lattice of the crystalline chromium deposit obtained in accordance with the present invention.
In one embodiment, the crystalline chromium deposit in accordance with the invention has a {111} preferred orientation.
In one embodiment, the crystalline chromium deposit is substantially free of macrocracking. In one embodiment, the crystalline chromium deposit does not form macrocracks when heated to a temperature up to about 300° C. In one embodiment, the crystalline chromium deposit does not change its crystalline structure when heated to a temperature up to about 300° C.
In one embodiment, the crystalline chromium deposit further includes carbon, nitrogen and sulfur in the chromium deposit.
In one embodiment, the crystalline chromium deposit contains from about 1.0 wt. % to about 10 wt. % sulfur. In another embodiment, the chromium deposit contains from about 1.5 wt. % to about 6 wt. % sulfur. In another embodiment, the chromium deposit contains from about 1.7 wt. % to about 4 wt. % sulfur. The sulfur is in the deposit present as elemental sulfur and may be a part of crystal lattice, i.e., replacing and thus taking the position of a chromium atom in the crystal lattice or taking a place in the tetrahedral or octahedral hole positions and distorting the lattice. In one embodiment, the source of sulfur may be a divalent sulfur compound. More details on exemplary sulfur sources are provided below. In one embodiment, instead of or in addition to sulfur, the deposit contains selenium and/or tellurium.
It is noted that some forms of crystalline chromium deposited from hexavalent chromium baths contain sulfur, but the sulfur content of such chromium deposits is substantially lower than the sulfur content of the crystalline chromium deposits in accordance with the present invention.
In one embodiment, the crystalline chromium deposit contains from about 0.1 to about 5 wt % nitrogen. In another embodiment, the crystalline chromium deposit contains from about 0.5 to about 3 wt % nitrogen. In another embodiment the crystalline chromium deposit contains about 0.4 weight percent nitrogen.
In one embodiment, the crystalline chromium deposit contains from about 0.1 to about 5 wt % carbon. In another embodiment, the crystalline chromium deposit contains from about 0.5 to about 3 wt % carbon. In another embodiment the crystalline chromium deposit contains about 1.4 wt. % carbon. In one embodiment, the crystalline chromium deposit contains an amount of carbon less than that amount which renders the chromium deposit amorphous. That is, above a certain level, in one embodiment, above about 10 wt. %, the carbon renders the chromium deposit amorphous, and therefore takes it out of the scope of the present invention. Thus, the carbon content should be controlled so that it does not render the chromium deposit amorphous. The carbon may be present as elemental carbon or as carbide carbon. If the carbon is present as elemental, it may be present either as graphitic or as amorphous.
In one embodiment, the crystalline chromium deposit contains from about 1.7 wt. % to about 4 wt. % sulfur, from about 0.1 wt. % to about 5 wt. % nitrogen, and from about 0.1 wt. % to about 10 wt. % carbon.
The crystalline chromium deposit of the present invention is electrodeposited from a trivalent chromium electroplating bath. The trivalent chromium bath is substantially free of hexavalent chromium. In one embodiment, the bath is free of detectable amounts of hexavalent chromium. The trivalent chromium may be supplied as chromic chloride, CrCl3, chromic fluoride, CrF3, chromic nitrate, Cr(NO3)3, chromic oxide Cr2O3, chromic phosphate CrPO4, or in a commercially available solution such as chromium hydroxy dichloride solution, chromic chloride solution, or chromium sulfate solution, e.g., from McGean Chemical Company or Sentury Reagents. Trivalent chromium is also available as chromium sulfate/sodium or potassium sulfate salts, e.g., Cr(OH)SO4.Na2SO4, often referred to as chrometans or kromsans, chemicals often used for tanning of leather, and available from companies such as Elementis, Lancashire Chemical, and Soda Sanayii. As noted below, the trivalent chromium may also be provided as chromic formate, Cr(HCOO)3 from Sentury Reagents.
The concentration of the trivalent chromium may be in the range from about 0.1 molar (M) to about 5 M. The higher the concentration of trivalent chromium, the higher the current density that can be applied without resulting in a dendritic deposit, and consequently the faster the rate of crystalline chromium deposition that can be achieved.
The trivalent chromium bath may further include an organic additive such as formic acid or a salt thereof, such as one or more of sodium formate, potassium formate, ammonium formate, calcium formate, magnesium formate, etc. Other organic additives, including amino acids such as glycine and thiocyanate may also be used to produce crystalline chromium deposits from trivalent chromium and their use is within the scope of one embodiment of this invention. Chromium (III) formate, Cr(HCOO)3, could also be used as a source of both trivalent chromium and formate.
The trivalent chromium bath may further include a source of nitrogen, which may be in the form of ammonium hydroxide or a salt thereof, or may be a primary, secondary or tertiary alkyl amine, in which the alkyl group is a C1-C6 alkyl. In one embodiment, the source of nitrogen is other than a quaternary ammonium compound. In addition to amines, amino acids, hydroxy amines such as quadrol and polyhydric alkanolamines, can be used as the source of nitrogen. In one embodiment of such nitrogen sources, the additives include C1-C6 alkyl groups. In one embodiment, the source of nitrogen may be added as a salt, e.g., an amine salt such as a hydrohalide salt.
As noted above, the crystalline chromium deposit may include carbon. The carbon source may be, for example, the organic compound such as formic acid or formic acid salt included in the bath. Similarly, the crystalline chromium may include oxygen and hydrogen, which may be obtained from other components of the bath including electrolysis of water, or may also be derived from the formic acid or salt thereof, or from other bath components.
In addition to the chromium atoms in the crystalline chromium deposit, other metals may be co-deposited. As will be understood by those of skill in the art, such metals may be suitably added to the trivalent chromium electroplating bath as desired to obtain various crystalline alloys of chromium in the deposit. Such metals include, but are not necessarily limited to, Re, Cu, Fe, W, Ni, Mn, and may also include, for example, P (phosphorus). In fact, all elements electrodepositable from aqueous solution, directly or by induction, as described by Pourbaix or by Brenner, may be alloyed in this process. In one embodiment, the alloyed metal is other than aluminum. As is known in the art, metals electrodepositable from aqueous solution include: Ag, As, Au, Bi, Cd, Co, Cr, Cu, Ga, Ge, Fe, In, Mn, Mo, Ni, P, Pb, Pd, Pt, Rh, Re, Ru, S, Sb, Se, Sn, Te, Tl, W and Zn, and inducible elements include B, C and N. As will be understood by those of skill in the art, the co-deposited metal or atom is present in an amount less than the amount of chromium in the deposit, and the deposit obtained thereby should be body-centered cubic crystalline, as is the crystalline chromium deposit of the present invention obtained in the absence of such co-deposited metal or atom.
The trivalent chromium bath further comprises a pH of at least 4.0, and the pH can range up to at least about 6.5. In one embodiment, the pH of the trivalent chromium bath is in the range from about 4.5 to about 6.5, and in another embodiment the pH of the trivalent chromium bath is in the range from about 4.5 to about 6, and in another embodiment, the pH of the trivalent chromium bath is in the range from about 5 to about 6, and in one embodiment, the pH of the trivalent chromium bath is about 5.5.
In one embodiment, the trivalent chromium bath is maintained at a temperature in the range from about 35° C. to about 115° C. or the boiling point of the solution, whichever is less, during the process of electrodepositing the crystalline chromium deposit of the present invention. In one embodiment, the bath temperature is in the range from about 45° C. to about 75° C., and in another embodiment, the bath temperature is in the range from about 50° C. to about 65° C., and in one embodiment, the bath temperature is maintained at about 55° C., during the process of electrodepositing the crystalline chromium deposit.
During the process of electrodepositing the crystalline chromium deposit of the present invention, the electrical current is applied at a current density of at least about 10 amperes per square decimeter (A/d m2). In another embodiment, the current density is in the range from about 10 A/dm2 to about 200 A/dm2, and in another embodiment, the current density is in the range from about 10 A/dm2 to about 100 A/dm2, and in another embodiment, the current density is in the range from about 20 A/dm2 to about 70 A/dm2, and in another embodiment, the current density is in the range from about 30 A/dm2 to about 60 A/dm2, during the electrodeposition of the crystalline chromium deposit from the trivalent chromium bath in accordance with the present invention.
During the process of electrodepositing the crystalline chromium deposit of the present invention, the electrical current may be applied using any one or any combination of two or more of direct current, pulse waveform or pulse periodic reverse waveform.
Thus, in one embodiment, the present invention provides a process for electrodepositing a crystalline chromium deposit on a substrate, including steps of:
providing an aqueous electroplating bath comprising trivalent chromium, formic acid or a salt thereof and at least one source of divalent sulfur, and substantially free of hexavalent chromium;
immersing a substrate in the electroplating bath; and
applying an electrical current to deposit a crystalline chromium deposit on the substrate, wherein the chromium deposit is crystalline as deposited.
In one embodiment, the crystalline chromium deposit obtained from this process has a lattice parameter of 2.8895+/−0.0025 Å. In one embodiment, the crystalline chromium deposit obtained from this process has a preferred orientation (“PO”).
In another embodiment, the present invention provides a process for electrodepositing a crystalline chromium deposit on a substrate, including steps of:
providing an electroplating bath comprising trivalent chromium, formic acid and substantially free of hexavalent chromium;
immersing a substrate in the electroplating bath; and
These processes in accordance with the invention may be carried out under the conditions described herein, and in accordance with standard practices for electrodeposition of chromium.
As noted above, a source of divalent sulfur is preferably provided in the trivalent chromium electroplating bath. A wide variety of divalent sulfur-containing compounds can be used in accordance with the present invention.
In one embodiment, the source of divalent sulfur may include one or a mixture of two or more of a compound having the general formula (I):
X1—R1—(S)n—R2—X2 (I)
wherein in (I), X1 and X2 may be the same or different and each of X1 and X2 independently comprise hydrogen, halogen, amino, cyano, nitro, nitroso, azo, alkylcarbonyl, formyl, alkoxycarbonyl, aminocarbonyl, alkylaminocarbonyl, dialkylaminocarbonyl, carboxyl (as used herein, “carboxyl” includes all forms of carboxyl groups, e.g., carboxylic acids, carboxylic alkyl esters and carboxylic salts), carboxylate, sulfonate, sulfinate, phosphonate, phosphinate, sulfoxide, carbamate, polyethoxylated alkyl, polypropoxylated alkyl, hydroxyl, halogen-substituted alkyl, alkoxy, alkyl sulfate ester, alkylthio, alkylsulfinyl, alkylsulfonyl, alkylphosphonate or alkylphosphinate, wherein the alkyl and alkoxy groups are C1-C6, or X1 and X2 taken together may form a bond from R1 to R2, thus forming a ring containing the R1 and R2 groups,
wherein R1 and R2 may be the same or different and each of R1 and R2 independently comprise a single bond, alkyl, allyl, alkenyl, alkynyl, cyclohexyl, aromatic and heteroaromatic rings, alkoxycarbonyl, aminocarbonyl, alkylaminocarbonyl, dialkylaminocarbonyl, polyethoxylated and polypropoxylated alkyl, wherein the alkyl groups are C1-C6, and
wherein n has an average value ranging from 1 to about 5.
In one embodiment, the source of divalent sulfur may include one or a mixture of two or more of a compound having the general formula (IIa) and/or (IIb):
wherein in (IIa) and (IIb), R3, R4, R5 and R6 may be the same or different and independently comprise hydrogen, halogen, amino, cyano, nitro, nitroso, azo, alkylcarbonyl, formyl, alkoxycarbonyl, aminocarbonyl, alkylaminocarbonyl, dialkylaminocarbonyl, carboxyl, sulfonate, sulfinate, phosphonate, phosphinate, sulfoxide, carbamate, polyethoxylated alkyl, polypropoxylated alkyl, hydroxyl, halogen-substituted alkyl, alkoxy, alkyl sulfate ester, alkylthio, alkylsulfinyl, alkylsulfonyl, alkylphosphonate or alkylphosphinate, wherein the alkyl and alkoxy groups are C1-C6,
wherein X represents carbon, nitrogen, oxygen, sulfur, selenium or tellurium and in which m ranges from 0 to about 3,
wherein n has an average value ranging from 1 to about 5, and
wherein each of (IIa) or (IIb) includes at least one divalent sulfur atom.
In one embodiment, the source of divalent sulfur may include one or a mixture of two or more of a compound having the general formula (IIIa) and/or (IIIb):
wherein, in (IIIa) and (IIIb), R3, R4, R5 and R6 may be the same or different and independently comprise hydrogen, halogen, amino, cyano, nitro, nitroso, azo, alkylcarbonyl, formyl, alkoxycarbonyl, aminocarbonyl, alkylaminocarbonyl, dialkylaminocarbonyl, carboxyl, sulfonate, sulfinate, phosphonate, phosphinate, sulfoxide, carbamate, polyethoxylated alkyl, polypropoxylated alkyl, hydroxyl, halogen-substituted alkyl, alkoxy, alkyl sulfate ester, alkylthio, alkylsulfinyl, alkylsulfonyl, alkylphosphonate or alkylphosphinate, wherein the alkyl and alkoxy groups are C1-C6,
wherein X represents carbon, nitrogen, sulfur, selenium or tellurium and in which m ranges from 0 to about 3,
wherein n has an average value ranging from 1 to about 5, and
wherein each of (IIIa) or (IIIb) includes at least one divalent sulfur atom.
In one embodiment, in any of the foregoing sulfur containing compounds, the sulfur may be replaced by selenium or tellurium. Exemplary selenium compounds include seleno-DL-methionine, seleno-DL-cystine, other selenides, R—Se—R′, diselenides, R—Se—Se—R′ and selenols, R—Se—H, where R and R′ independently may be an alkyl or aryl group having from 1 to about 20 carbon atoms, which may include other heteroatoms, such as oxygen or nitrogen, similar to those disclosed above for sulfur. Exemplary tellurium compounds include ethoxy and methoxy telluride, Te(OC2H5)4 and Te(OCH3)4.
As will be understood, the substituents used are preferably selected so that the compounds thus obtained remain soluble in the electroplating baths of the present invention.
In Table 1 comparative examples of various aqueous hexavalent chromic acid containing electrolytes that produce functional chromium deposits are listed, the crystallographic properties of the deposit tabulated, and reported elemental composition based upon C, O, H, N and S analysis.
In Table 2 comparative examples of trivalent chromium process solutions deemed by the Ecochrome project to be the best available technology are tabulated. The Ecochrome project was a multiyear European Union sponsored program (G1RD CT-2002-00718) to find an efficient and high performance hard chromium alternative based upon trivalent chromium (see, Hard Chromium Alternatives Team (HCAT) Meeting, San Diego, Calif., Jan. 24-26, 2006). The three processes are from Cidetec, a consortium based in Spain; ENSME, a consortium based in France; and, Musashi, a consortium based in Japan. In this table, where no chemical formula is specifically listed, the material is believed to be proprietary in the presentations from which these data were obtained, and is not available.
In the Table 2 comparative examples, the EC3 example contains aluminum chloride. Other trivalent chromium solutions containing aluminum chloride have been described. Suvegh et al. (Journal of Electroanalytical Chemistry 455 (1998) 69-73) use an electrolyte comprising 0.8 M [Cr(H2O)4Cl2]Cl.2H2O, 0.5 M NH4Cl, 0.5 M NaCl, 0.15 M H3BO3, 1 M glycine, and 0.45 M AlCl3, pH not described. Hong et al. (Plating and Surface Finishing, March 2001) describe an electrolyte comprising mixtures of carboxylic acids, a chromium salt, boric acid, potassium chloride, and an aluminum salt, at pH 1-3). Ishida et al. (Journal of the Hard Chromium Platers Association of Japan 17, No. 2, Oct. 31, 2002) describe solutions comprising 1.126 M [Cr(H2O)4Cl2]Cl.2H2O, 0.67 M glycine, 2.43 M NH4Cl, and 0.48 M H3BO3 to which varying amounts of AlCl3.6H2O, from 0.11 to 0.41 M were added; pH was not described. Of these four references disclosing aluminum chloride in the trivalent chromium bath, only Ishida et al. contends that the chromium deposit is crystalline, stating that crystalline deposits accompany increasing concentrations of AlCl3. However, repeated attempts by the present inventors to replicate the experiment and produce crystalline deposits have failed. It is believed that an important experimental variable is not described by Ishida et al. Therefore, it is considered that Ishida et al. fails to teach how to make a reliably consistent crystalline chromium deposit.
In Table 3 various aqueous (“T”) trivalent chromium-containing electrolytes and one ionic liquid (“IL”) trivalent chromium-containing electrolyte, all of which can produce chromium deposits in excess of one micron thickness, are listed and the crystallographic properties of the deposit tabulated.
In Table 4 the various deposits from Tables 1, 2 and 3 are compared using standard test methods frequently used for evaluation of as-deposited functional chromium electrodeposits. From this table it can be observed that amorphous deposits, and deposits that are not BCC (body centered cubic) do not pass all the necessary initial tests.
In accordance with industrial requirements for replacement of hexavalent chromium electrodeposition baths, the deposits from trivalent chromium electrodeposition baths must be crystalline to be effective and useful as a functional chromium deposit. It has been found that certain additives can be used together with adjustments in the process variables of the electrodeposition process to obtain a desirably crystalline chromium deposit from a trivalent chromium bath that is substantially free of hexavalent chromium. Typical process variables include current density, solution temperature, solution agitation, concentration of additives, manipulation of the applied current waveform, and solution pH. Various tests may be used to accurately assess the efficacy of a particular additive, including, e.g., X-ray diffraction (XRD) (to study the structure of the chromium deposit), X-ray photoelectron spectroscopy (XPS) (for determination of components of the chromium deposit, greater than about 0.2-0.5 wt. %), elastic recoil determination (ERD)(for determination of hydrogen content), and electron microscopy (for determination of physical or morphological characteristics such as cracking).
In the prior art, it has been generally and widely considered that chromium deposition from trivalent chromium baths must occur at pH values less than about 2.5. However, there are isolated trivalent chromium plating processes, including brush plating processes, where higher pH's have been used, although the higher pH's used in these brush plating solutions do not result in a crystalline chromium deposit. Therefore, in order to assess the efficacy of various additives, stable, high pH electrolytes were tested as well as the commonly accepted low pH electrolytes.
From the data shown in Table 5 it is apparent that compounds that have divalent sulfur in their structure induce crystallization when chromium is electrodeposited from a trivalent chromium solution, at about the above-stated concentrations and when the pH of the bath is greater than about 4, in which the chromium crystals have the lattice parameter of 2.8895+/−0.0025 Å, in accordance with the present invention. In one embodiment, other divalent sulfur compounds can be used in the baths described herein to electrodeposit crystalline chromium having the lattice parameter of the present invention. In one embodiment, compounds having sulfur, selenium or tellurium, when used as described herein, also induce crystallization of chromium. In one embodiment, the selenium and tellurium compounds correspond to the above-identified sulfur compounds, and like the sulfur compounds, result in the electrodeposition of crystalline chromium having a lattice parameter of 2.8895+/−0.0025 Å.
To further illustrate the induction of crystallization, studies on crystallization inducing additives using electrolyte T3 at pH 5.5 and temperature 50° C. with identical cathode current densities of 40 A/dm2 and plating times of thirty minutes using brass substrate are reported in Table 6. After plating is complete the coupons are examined using X-ray diffraction, X-ray induced X-ray fluorescence for thickness determination, and electron induced X-ray fluorescence with an energy dispersive spectrophotometer to measure sulfur content. Table 6 summarizes the data. The data may suggest that it is not only the presence of a divalent sulfur compound in the solution at a concentration exceeding a threshold concentration that induces crystallization but the presence of sulfur in the deposit, as well.
The following Table 7 provides additional data relating to electroplating baths of trivalent chromium in accordance with the present invention.
The above examples are prepared with direct current and without the use of complex cathodic waveforms such as pulse or periodic reverse pulse plating, although such variations on the applied electrical current are within the scope of the present invention. All of the examples in Table 7 that are crystalline have a lattice constant of 2.8895+/−0.0025 Å, as deposited.
In a further example of the utility of this invention pulse depositions are performed using simple pulse waveforms generated with a Princeton Applied Research Model 273A galvanostat equipped with a power booster interface and a Kepco bipolar +/−10 A power supply, using process P1, with and without thiomorpholine. Pulse waveforms are square wave, 50% duty cycle, with sufficient current to produce a 40 A/dm2 current density overall. The frequencies employed are 0.5 Hz, 5 Hz, 50 Hz, and 500 Hz. At all frequencies the deposits from process P1 without thiomorpholine are amorphous while the deposits from process P1 with thiomorpholine are crystalline as deposited.
In a further example of the utility of this invention pulse depositions are performed using simple pulse waveforms generated with a Princeton Applied Research Model 273A galvanostat equipped with a power booster interface and a Kepco bipolar +/−10 A power supply, using process P1, with and without thiomorpholine. Pulse waveforms are square wave, 50% duty cycle, with sufficient current to produce a 40 A/dm2 current density overall. The frequencies employed are 0.5 Hz, 5 Hz, 50 Hz, and 500 Hz. At all frequencies the deposits from process P1 without thiomorpholine are amorphous while the deposits from process P1 with thiomorpholine are crystalline as deposited, and have a lattice constant of 2.8895+/−0.0025 Å.
Similarly the electrolyte T5 is tested with and without thiosalicylic acid at a concentration of 2 g/L using a variety of pulse waveforms having current ranges of 66-109 A/dm2 with pulse durations from 0.4 to 200 ms and rest durations of 0.1 to 1 ms including periodic reverse waveforms with reverse current of 38-55 A/dm2 and durations of 0.1 to 2 ms. In all cases, without thiosalicylic acid the deposit is amorphous, with thiosalicylic acid the deposit is crystalline, and has a lattice constant of 2.8895+/−0.0025 Å.
In one embodiment, the crystalline chromium deposits are homogeneous, without the deliberate inclusion of particles, and have a lattice constant of 2.8895+/−0.0025 Å. For example, particles of alumina, Teflon, silicon carbide, tungsten carbide, titanium nitride, etc. may be used with the present invention to form crystalline chromium deposits including such particles within the deposit. Use of such particles with the present invention is carried out substantially in the same manner as is known from prior art processes.
The foregoing examples use anodes of platinized titanium. However, the invention is in no way limited to the use of such anodes. In one embodiment, a graphite anode may be used as an insoluble anode. In another embodiment, a soluble chromium or ferrochromium anodes may be used.
In one embodiment, the anodes may be isolated from the bath. In one embodiment, the anodes may be isolated by use of a fabric, which may be either tightly knit or loosely woven. Suitable fabrics include those known in the art for such use, including, e.g., cotton and polypropylene, the latter available from Chautauqua Metal Finishing Supply, Ashville, N.Y. In another embodiment, the anode may be isolated by use of anionic or cationic membranes, for example, such as perfluorosulfonic acid membranes sold under the tradenames NAFION® (DuPont), ACIPLEX® (Asahi Kasei), FLEMION® (Asahi Glass) or others supplied by Dow or by Membranes International Glen Rock, N.J. In one embodiment, the anode may be placed in a compartment, in which the compartment is filled with an acidic, neutral, or alkaline electrolyte that differs from the bulk electrolyte, by an ion exchange means such as a cationic or anionic membrane or a salt bridge.
In one embodiment, the cathodic efficiency ranges from about 5% to about 80%, and in one embodiment, the cathodic efficiency ranges from about 10% to about 40%, and in another embodiment, the cathodic efficiency ranges from about 10% to about 30%.
In another embodiment additional alloying of the crystalline chromium electrodeposit, in which the chromium has a lattice constant of 2.8895+/−0.0025 Å, may be performed using ferrous sulfate and sodium hypophosphite as sources of iron and phosphorous with and without the addition of 2 g/L thiosalicylic acid. Additions of 0.1 g/L to 2 g/L of ferrous ion to electrolyte T7 result in alloys containing 2 to 20% iron. The alloys are amorphous without the addition of thiosalicylic acid. Additions of 1 to 20 g/L sodium hypophosphite resulted in alloys containing 2 to 12% phosphorous in the deposit. The alloys were amorphous unless thiosalicylic acid is added.
In another embodiment, crystalline chromium deposits having a lattice constant of 2.8895+/−0.0025 Å are obtained from electrolyte T7 with 2 g/L thiosalicylic acid agitated using ultrasonic energy at a frequency of 25 kHz and 0.5 MHz. The resulting deposits are crystalline, having a lattice constant of 2.8895+/−0.0025 Å, bright, and there is no significant variation in deposition rate regardless of the frequency used.
It is noted that, throughout the specification and claims, the numerical limits of the disclosed ranges and ratios may be combined, and are deemed to include all intervening values. Thus, for example, where ranges of 1-100 and 10-50 are specifically disclosed, ranges of 1-10, 1-50, 10-100 and 50-100 are deemed to be within the scope of the disclosure, as are the intervening integral values. Furthermore, all numerical values are deemed to be preceded by the modifier “about”, whether or not this term is specifically stated. Furthermore, when the chromium deposit is electrodeposited from a trivalent chromium bath as disclosed herein in accordance with the present invention, and the thus-formed deposit is stated herein as being crystalline, it is deemed to have a lattice constant of 2.8895+/−0.0025 Å, whether or not this lattice constant is specifically stated. Finally, all possible combinations of disclosed elements and components are deemed to be within the scope of the disclosure, whether or not specifically mentioned.
While the principles of the invention have been explained in relation to certain particular embodiments, and are provided for purposes of illustration, it is to be understood that various modifications thereof will become apparent to those skilled in the art upon reading the specification. Therefore, it is to be understood that the invention disclosed herein is intended to cover such modifications as fall within the scope of the appended claims. The scope of the invention is limited only by the scope of the claims.
The present application is related to and claims benefit under 35 U.S.C. §119 to U.S. Provisional Application No. 60/788,387, filed 31 Mar. 2006, the entirety of which is hereby incorporated herein by reference.
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