Electrolytic process for forming a mineral

Abstract

The disclosure relates to a process for forming a deposit on the surface of a metallic or conductive surface. The process employs an electrolytic process to deposit a mineral containing coating or film upon a metallic or conductive surface.

Description

FIELD OF THE INVENTION

The instant invention relates to a process for forming a deposit on the surface of a metallic or conductive surface. The process employs an electrolytic process to deposit a mineral containing coating or film upon a metallic, metal containing or conductive surface.

BACKGROUND OF THE INVENTION

Silicates have been used in electrocleaning operations to clean steel, tin, among other surfaces. Electrocleaning is typically employed as a cleaning step prior to an electroplating operation. Using "Silicates As Cleaners In The Production of Tinplate" is described by L. J. Brown in February 1966 edition of Plating; hereby incorporated by reference.

Processes for electrolytically forming a protective layer or film by using an anodic method are disclosed by U.S. Pat. No. 3,658,662 (Casson, Jr. et al.), and United Kingdom Patent No. 498,485; both of which are hereby incorporated by reference.

U.S. Pat. No. 5,352,342 to Riffe, which issued on Oct. 4, 1994 and is entitled "Method And Apparatus For Preventing Corrosion Of Metal Structures" that describes using electromotive forces upon a zinc solvent containing paint; hereby incorporated by reference.

SUMMARY OF THE INVENTION

The instant invention solves problems associated with conventional practices by providing a cathodic method for forming a protective layer upon a metallic or metal containing substrate. The cathodic method is normally conducted by immersing an electrically conductive substrate into a silicate containing bath wherein a current is passed through the bath and the substrate is the cathode. A mineral layer comprising an amorphous matrix surrounding or incorporating metal silicate crystals forms upon the substrate. The characteristics of the mineral layer are described in greater detail in the copending and commonly patent applications listed below. The mineral layer imparts improved corrosion resistance, among other properties, to the underlying substrate.

The inventive process is a marked improvement over conventional methods by obviating the need for solvents or solvent containing systems to form a corrosion resistant layer, i.e., a mineral layer. In contrast, to conventional methods the inventive process is substantially solvent free. By "substantially solvent free" it is meant that less than about 5 wt. %, and normally less than about 1 wt. % volatile organic compounds (V.O.C.s) are present in the electrolytic environment.

The inventive process is also a marked improvement over conventional methods by reducing, if not eliminating, chrome and/or phosphorous containing compounds. While the inventive process can be employed to enhance chromated or phosphated surfaces, the inventive process can replace these surfaces with a more environmentally desirable surface. The inventive process, therefore, can be "substantially chromate free" and "substantially phosphate free" and in turn produce articles that are also substantially chromate free and substantially phosphate free. By substantially chromate free and substantially phosphate free it is meant that less than 5 wt. % and normally about 0 wt. % chromates or phosphates are present in a process for producing an article or the resultant article.

In contrast to conventional electrocleaning processes, the instant invention employs silicates in a cathodic process for forming a mineral layer upon the substrate. Conventional electro-cleaning processes sought to avoid formation of oxide containing products such as greenalite whereas the instant invention relates to a method for forming silicate containing products, i.e., a mineral.

CROSS REFERENCE TO RELATED PATENTS AND PATENT APPLICATIONS

The subject matter of the instant invention is related to copending and commonly assigned Non-Provisional U.S. patent application Ser. Nos. 08/850,323; 08/850,586; and 09/016,853 (EL001RH-6, EL001RH-7 and EL001RH-8), filed respectively on May 2, 1997 and Jan. 30, 1998, and 08/1791,337 (Attorney Docket No. EL001RH-4 filed on Jan. 31, 1997) in the names of Robert L. Heimann et al., and all currently pending, as a continuation in part of Ser. No. 08/634,215 (filed on Apr. 18, 1996), now abandoned, in the names of Robert L. Heimann et al., and entitled "Corrosion Resistant Buffer System for Metal Products", which is a continuation in part of Non-Provisional U.S. patent application Ser. No. 08/476,271 (filed on Jun. 7, 1995), now abandoned, in the names of Heimann et al., and corresponding to WIPO Patent Application Publication No. WO 96/12770, which in turn is a continuation in part of Non-Provisional U.S. patent application Ser. No. 08/327,438 (filed on Oct. 21, 1994), now U.S. Pat. No. 5,714,093.

The subject matter of this invention is related to Non-Provisional patent application Ser. No. 09/016,849 (Attorney Docket No. EL004RH-1), filed on Jan. 30, 1998, currently pending, and entitled "Corrosion Protective Coatings". The subject matter of this invention is also related to Non-Provisional patent application Ser. No. 09/016,462 (Attorney Docket No. EL005NM-1), filed on Jan. 30, 1998 and entitled "Aqueous Gel Compositions and Use Thereof", now U.S. Pat. No. 6,033,495. The disclosure of the previously identified patents, patent applications and publications is hereby incorporated by reference.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a schematic drawing of the circuit and apparatus which can be employed for practicing an aspect of the invention.

FIG. 2 is a schematic drawing of one process that employs the inventive electrolytic method.

DETAILED DESCRIPTION

The instant invention relates to a process for depositing or forming a mineral containing coating or film upon a metallic or an electrically conductive surface. The process employs a mineral containing solution e.g., containing soluble mineral components, and utilizes an electrically enhanced method to obtain a mineral coating or film upon a metallic or conductive surface. By "mineral containing coating", "mineralized film" or "mineral" it is meant to refer to a relatively thin coating or film which is formed upon a metal or conductive surface wherein at least a portion of the coating or film includes at least one metal containing mineral, e.g., an amorphous phase or matrix surrounding or incorporating crystals comprising a zinc disilicate. Mineral and Mineral Containing are defined in the previously identified Copending and Commonly Assigned Patents and Patent Applications; incorporated by reference. By "electroyltic" or "electrodeposition" or "electrically enhanced", it is meant to refer to an environment created by passing an electrical current through a silicate containing medium while in contact with an electrically conductive substrate and wherein the substrate functions as the cathode.

The electroyltic environment can be established in any suitable manner including immersing the substrate, applying a silicate containing coating upon the substrate and thereafter applying an electrical current, among others. The preferred method for establishing the environment will be determined by the size of the substrate, electrodeposition time, among other parameters known in the electrodeposition art. The inventive process can be operated on a batch or continuous basis. The electrolytic environment can be preceded by or followed with conventional post and/or pre-treatments known in this art such as cleaning or rinsing, e.g., sonic cleaning, double counter-current cascading flow; alkali or acid treatments.

The silicate containing medium can be a fluid bath, gel, spray, among other methods for contacting the substrate with the silicate medium. Examples of the silicate medium comprise a bath containing at least one silicate, a gel comprising at least one silicate and a thickener, among others. The medium can comprise a bath comprising at least one of potassium silicate, calcium silicate, sodium silicate, among other silicates. Normally, the bath comprises sodium silicate.

The metal surface refers to a metal article as well as a non-metallic or an electrically conductive member having an adhered metal or conductive layer. Examples of suitable metal surfaces comprise at least one member selected from the group consisting of galvanized surfaces, zinc, iron, steel, brass, copper, nickel, tin, aluminum, lead, cadmium, magnesium, alloys thereof, among others. While the inventive process can be employed to coat a wide range of metal surfaces, e.g., copper, aluminum and ferrous metals, the mineral layer can be formed on a non-conductive substrate having at least one surface coated with an electrically conductive material, e.g., a metallized polymeric sheet or ceramic material encapsulated within a metal. Conductive surfaces can also include carbon or graphite as well as conductive polymers (polyaniline for example).

The metal surface can possess a wide range of sizes and configurations, e.g., fibers, drawn wires or wire strand/rope, rods, particles, fasteners, among others. The limiting characteristic of the inventive process to treat a metal surface is dependent upon the ability of the electrical current to contact the metal surface. That is, similar to conventional electroplating technologies, a mineral surface may be difficult to apply upon a metal surface defining hollow areas or voids. This difficulty can be solved by using a conformal cathode.

The mineral coating can enhance the surface characteristics of the metal or conductive surface such as resistance to corrosion, protect carbon (fibers for example) from oxidation, stress crack corrosion, hardness and improve bonding strength in composite materials, and reduce the conductivity of conductive polymer surfaces including potential application in sandwich type materials. The mineral coating can also affect the electrical and magnetic properties of the surface.

In one aspect of the invention, the inventive process is employed for improving the cracking and oxidation resistance of aluminum, copper or lead containing substrates. For example, lead, which is used extensively in battery production, is prone to corrosion that in turn causes cracking, e.g., inter-granular corrosion. The inventive process can be employed for promoting grain growth of aluminum, copper and lead substrates as well as reducing the impact of surface flaws. Without wishing to be bound by any theory or explanation, it is believed that the lattice structure of the mineral layer formed in accordance with the inventive process on these 3 types of substrates would be a partially polymerized silicate. These lattices could incorporate a disilicate structure, or a chain silicate such as a pyroxene. A partially polymerized silicate lattice offers structural rigidity without being brittle. In order to achieve a stable partially polymerized lattice, metal cations would preferably occupy the lattice to provide charge stability. Aluminum has the unique ability to occupy either the octahedral site or the tetrahedral site in place of silicon. The +3 valence of aluminum would require additional metal cations to replace the +4 valance of silicon. In the case of lead application, additional cations could be, but are not limited to a +2 lead ion.

In an aspect of the invention, an electrogalvanized panel, e.g., a zinc surface, is coated electrolytically by being placed into an aqueous sodium silicate solution. After being placed into the silicate solution, a mineral coating or film containing silicates is deposited by using low voltage and low current.

In one aspect of the invention, the metal surface, e.g., zinc, aluminum, steel, lead and alloys thereof; has an optional pretreated. By "pretreated" it is meant to refer to a batch or continuous process for conditioning the metal surface to clean it and condition the surface to facilitate acceptance of the mineral or silicate containing coating e.g., the inventive process can be employed as a step in a continuous process for producing corrosion resistant coil steel. The particular pretreatment will be a function of composition of the metal surface and desired composition of mineral containing coating/film to be formed on the surface. Examples of suitable pre-treatments comprise at least one of cleaning, e.g., sonic cleaning, activating, and rinsing. One suitable pretreatment process for steel comprises:

1) 2 minute immersion in a 3:1 dilution of Metal Prep 79 (Parker Amchem), 2) two deionized rinses, 3) 10 second immersion in a pH 14 sodium hydroxide solution, 4) remove excess solution and allow to air dry, 5) 5 minute immersion in a 50% hydrogen peroxide solution, 6) remove excess solution and allow to air dry.

In another aspect of the invention, the metal surface is pretreated by anodically cleaning the surface. Such cleaning can be accomplished by immersing the work piece or substrate into a medium comprising silicates, hydroxides, phosphates and carbonates. By using the work piece as the anode in a DC cell and maintaining a current of about 100 mA/cm.sup.2, the process can generate oxygen gas. The oxygen gas agitates the surface of the workpiece while oxidizing the substrate's surface. The surface can also be agitated mechanically by using conventional vibrating equipment. If desired, the amount of oxygen or other gas present during formation of the mineral layer can be increased by physically introducing such gas, e.g., bubbling, pumping, among other means for adding gases.

In a further aspect of the invention, the silicate solution is modified to include one or more dopant materials. While the cost and handling characteristics of sodium silicate are desirable, at least one member selected from the group of water soluble salts, oxides and precursors of tungsten, molybdenum, chromium, titanium, zircon, vanadium, phosphorus, aluminum, iron, boron, bismuth, gallium, tellurium, germanium, antimony, niobium (also known as columbium), magnesium and manganese, mixtures thereof, among others, and usually, salts and oxides of aluminum and iron can be employed along with or instead of a silicate. The dopant can include fluorotitanic acid and salts thereof such as titanium hydrofluoride, ammonium fluorotitanate and sodium fluorotitanate; fluorozirconic acid and salts thereof such as H.sub.2 ZrF.sub.6, (NH.sub.4).sub.2 ZrF.sub.6 and Na.sub.2 ZrF.sub.6 ; among others. The dopants that can be employed for enhancing the mineral layer formation rate, modifying the chemistry of the mineral layer, as a diluent for the electrolyte or silicate containing medium. Examples of such dopants are iron salts (ferrous sulfate, nitrate), aluminum fluoride, fluorosilicates, mixtures thereof, among other sources of metals and halogens. The dopant materials can be introduced to the metal or conductive surface in pretreatment steps prior to electrodeposition, in post treatment steps following electrodeposition, and/or by alternating electrolytic contacts in solutions of dopants and solutions of silicates if the silicates will not form a stable solution with the dopants, e.g., one or more water soluble dopants. The presence of dopants in the electrolyte solution can be employed to form tailored mineral containing surfaces upon the metal or conductive surface, e.g., an aqueous sodium silicate solution containing aluminate can be employed to form a layer comprising oxides of silicon and aluminum.

The silicate solution can also be modified by adding water soluble polymers, and the electro-deposition solution itself can be in the form of a flowable gel consistency having a predetermined viscosity. A suitable composition can be obtained in an aqueous composition comprising about 3 wt % N-grade Sodium Silicate Solution (PQ Corp), optionally about 0.5 wt % Carbopol EZ-2 (BF Goodrich), about 5 to about 10 wt. % fumed silica, mixtures thereof, among others. Further, the aqueous silicate solution can be filled with a water dispersible polymer such as polyurethane to electro-deposit a mineral-polymer composite coating. The characteristics of the electro-deposition solution can be modified or tailored by using an anode material as a source of ions which can be available for codeposition with the mineral anions and/or one or more dopants. The dopants can be useful for building additional thickness of the electrodeposited mineral layer.

The following sets forth the parameters which may be employed for tailoring the inventive process to obtain a desirable mineral containing coating:

1. Voltage 2. Current Density 3. Apparatus or Cell Design 4. Deposition Time 5. Concentration of the N-grade sodium silicate solution 7. Type and concentration of anions in solution 8. Type and concentration of cations in solution 9. Composition/surface area of the anode 10. Composition/surface area of the cathode 11. Temperature 12. Pressure 13. Type and Concentration of Surface Active Agents

The specific ranges of the parameters above depend on the substrate to be deposited on and the intended composition to be deposited. Normally, the temperature of the electrolyte bath ranges from about 25.degree. to about 95.degree. C., the voltage from about 12 to 24 volts, an electrolyte solution concentration from about 5 to about 15 wt. % silicate, contact time with the electrolyte from about 10 to about 50 minutes and anode to cathode surface area ratio of about 0.5:1 to about 2:1. Items 1, 2, 7, and 8 can be especially effective in tailoring the chemical and physical characteristics of the coating. That is, items 1 and 2 can affect the deposition time and coating thickness whereas items 7 and 8 can be employed for introducing dopants that impart desirable chemical characteristics to the coating. The differing types of anions and cations can comprise at least one member selected from the group consisting of Group I metals, Group II metals, transition and rare earth metal oxides, oxyanions such as molybdate, phosphate, titanate, boron nitride, silicon carbide, aluminum nitride, silicon nitride, mixtures thereof, among others.

The mineral layer as well as the mineral layer formation process can be modified by varying the composition of the anode. Examples of suitable anodes comprise platinum, zinc, steel, tantalum, niobium, titanium, Monel.RTM. alloys, alloys thereof, among others. The anode can release ions into the electrolyte bath that can become incorporated within the mineral layer. Normally, ppm concentrations of anode ions are sufficient to affect the mineral layer composition.

The mineral layer formation process can be practiced in any suitable apparatus and methods. Examples of suitable apparatus comprise rack and barrel plating, brush plating, among other apparatus conventionally used in electroplating metals. The mineral layer formation process is better understood by referring to the drawings. Referring now to FIG. 2, FIG. 2 illustrates a schematic drawing of one process that employs the inventive electrolytic method. The process illustrated in FIG. 2 can be operated in a batch or continuous process. The articles having a metal surface to be treated (or workpiece) are first cleaned by an acid such as hydrochloric acid, rinsed with water, and rinsed with an alkali such as sodium hydroxide, rinsed again with water. The cleaning and rinsing can be repeated as necessary. If desired the acid/alkali cleaning can be replaced with a conventional sonic cleaning apparatus. The workpiece is then subjected to the inventive electrolytic method thereby forming a mineral coating upon at least a portion of the workpiece surface. The workpiece is removed from the electrolytic environment, dried and rinsed with water, e.g, a layer comprising, for example, silica and/or sodium carbonate can be removed by rinsing. Depending upon the intended usage of the dried mineral-coated workpiece, the workpiece can be coated with a secondary coating or layer. Examples of such secondary coatings or layers comprise one or more members of acrylic coatings (e.g., IRALAC), silanes, urethane, epoxies, among others. The secondary coatings can be applied by using an suitable conventional method such as immersing, dip-spin, spraying, among other methods. The secondary coatings can be employed for imparting a wide range of properties such as improved corrosion resistance to the underlying mineral layer, a temporary coating for shipping the mineral coated workpiece, among other utilities. The mineral coated workpiece, with or without the secondary coating, can be used as a finished product or a component to fabricate another article.

Without wishing to be bound by any theory or explanation a silica containing layer can be formed upon the mineral. The silica containing layer can be chemically or physically modified and employed as an intermediate or tie-layer. The tie-layer can be used to enhance bonding to paints, coatings, metals, glass, among other materials contacting the tie-layer. This can be accomplished by binding to the top silica containing layer one or more materials which contain alkyl, fluorine, vinyl, epoxy including two-part epoxy and powder paint systems, silane, hydroxy, amino, mixtures thereof, among other functionalities reactive to silica or silicon hydroxide. Alternatively, the silica containing layer can be removed by using conventional cleaning methods, e.g, rinsing with de-ionized water. The silica containing tie-layer can be relatively thin in comparison to the mineral layer 100-500 angstroms compared to the total thickness of the mineral which can be 1500-2500 angstroms thick.

In another aspect, the mineral without or without the aforementioned silica layer functions as an intermediate or tie-layer for one or more secondary coatings, e.g., silane containing secondary coatings. Examples of such secondary coatings and methods that can be complimentary to the instant invention are described in U.S. Pat. Nos. 5,759,629; 5,750,197; 5,539,031; 5,498,481; 5,478,655; 5,455,080; and 5,433,976. The disclosure of each of these U.S. Patents is hereby incorporated by reference. For example, improved corrosion resistance of a metal substrate can be achieved by using a secondary coating comprising at least one suitable silane in combination with a mineralized surface. Examples of suitable silanes comprise at least one members selected from the group consisting of tetra-ortho-ethyl-silicate (TEOS), bis-1,2-(triethoxysilyl) ethane (BSTE), vinyl silane or aminopropyl silane, among other organo functional silanes. The silane can bond with the mineralized surface and then the silane can crosslink thereby providing a protective top coat, or a surface for receiving an outer coating or layer. In some cases, it is desirable to sequencially apply the silanes. For example, a steel substrate, e.g., a fastener, can be treated to form a mineral layer, allowed to dry, rinsed in deionized water, coated with a 5% BSTE solution, coated again with a 5% vinyl silane solution, and powder coated with a thermoset epoxy paint (Corvel 10-1002 by Morton) at a thickness of 2 mils. The steel substrate was scribed using a carbide tip and exposed to ASTM B117 salt spray for 500 hours. After the exposure, the panels were removed and rinsed and allowed to dry for 1 hour. Using a spatula, the scribes were scraped, removing any paint due to undercutting, and the remaining gaps were measured. The tested panels showed no measurable gap beside the scribe.

One or more outer coatings or layers can be applied to the secondary coating. Examples of suitable outer coatings comprise at least one member selected from the group consisting of acrylics, epoxies, urethanes, silanes, oils, gels, grease, among others. An example of a suitable epoxy comprises a coating supplied by Magni Industries as B17 top coat. By selecting appropriate secondary and outer coatings for application upon the mineral, a corrosion resistant article can be obtained without chromating or phosphating. Such a selection can also reduce usage of zinc to galvanize iron containing surfaces, e.g., a steel surface is mineralized, coated with a silane containing coating and with an outer coating comprising an epoxy.

While the above description places particular emphasis upon forming a mineral containing layer upon a metal surface, the inventive process can be combined with or replace conventional metal pre or post treatment and/or finishing practices. Conventional post coating baking methods can be employed for modifying the physical characteristics of the mineral layer, remove water and/or hydrogen, among other modifications. The inventive mineral layer can be employed to protect a metal finish from corrosion thereby replacing conventional phosphating process, e.g., in the case of automotive metal finishing the inventive process could be utilized instead of phosphates and chromates and prior to coating application e.g., E-Coat. Further, the aforementioned aqueous mineral solution can be replaced with an aqueous polyurethane based solution containing soluble silicates and employed as a replacement for the so-called automotive E-coating and/or powder painting process. The mineral forming process can be employed for imparting enhanced corrosion resistance to electronic components, e.g., such as the electric motor shafts as demonstrated by Examples 10-11. The inventive process can also be employed in a virtually unlimited array of end-uses such as in conventional plating operations as well as being adaptable to field service. For example, the inventive mineral containing coating can be employed to fabricate corrosion resistant metal products that conventionally utilize zinc as a protective coating, e.g., automotive bodies and components, grain silos, bridges, among many other end-uses.

Moreover, depending upon the dopants and concentration thereof present in the mineral deposition solution, the inventive process can produce microelectronic films, e.g., on metal or conductive surfaces in order to impart enhanced electrical/magnetic and corrosion resistance, or to resist ultraviolet light and monotomic oxygen containing environments such as outer space.

The following Examples are provided to illustrate certain aspects of the invention and it is understood that such an Example does not limit the scope of the invention as defined in the appended claims. The x-ray photoelectron spectroscopy (ESCA) data in the following Examples demonstrate the presence of a unique metal disilicate species within the mineralized layer, e.g., ESCA measures the binding energy of the photoelectrons of the atoms present to determine bonding characteristics.

EXAMPLE 1

The following apparatus and materials were employed in this Example:

Standard Electrogalvanized Test Panels, ACT Laboratories 10% (by weight) N-grade Sodium Silicate solution 12 Volt EverReady.RTM. battery 1.5 Volt Ray-O-Vac.RTM. Heavy Duty Dry Cell Battery Triplett RMS Digital Multimeter 30 .mu.F Capacitor 29.8 k.OMEGA. Resistor

A schematic of the circuit and apparatus which were employed for practicing the Example are illustrated in FIG. 1. Referring now to FIG. 1, the aforementioned test panels were contacted with a solution comprising 10% sodium mineral and de-ionized water. A current was passed through the circuit and solution in the manner illustrated in FIG. 1. The test panels was exposed for 74 hours under ambient environmental conditions. A visual inspection of the panels indicated that a light-gray colored coating or film was deposited upon the test panel.

In order to ascertain the corrosion protection afforded by the mineral containing coating, the coated panels were tested in accordance with ASTM Procedure No. B117. A section of the panels was covered with tape so that only the coated area was exposed and, thereafter, the taped panels were placed into salt spray. For purposes of comparison, the following panels were also tested in accordance with ASTM Procedure No. B117, 1) Bare Electrogalvanized Panel, and 2) Bare Electrogalvanized Panel soaked for 70 hours in a 10% Sodium Mineral Solution. In addition, bare zinc phosphate coated steel panels(ACT B952, no Parcolene) and bare iron phosphate coated steel panels (ACT B1000, no Parcolene) were subjected to salt spray for reference.

The results of the ASTM Procedure are listed in the Table below:

______________________________________Panel Description Hours in B117 Salt Spray______________________________________Zinc phosphate coated steel 1Iron phosphate coated steel 1Standard Bare Electrogalvanize Panel .apprxeq.120Standard Panel with Sodium Mineral .apprxeq.120SoakCoated Cathode of the Invention 240+______________________________________

The above Table illustrates that the instant invention forms a coating or film which imparts markedly improved corrosion resistance. It is also apparent that the process has resulted in a corrosion protective film that lengthens the life of electrogalvanized metal substrates and surfaces.

ESCA analysis was performed on the zinc surface in accordance with conventional techniques and under the following conditions:

Analytical conditions for ESCA:

______________________________________Instrument Physical Electronics Model 5701 LSci______________________________________X-ray source Monochromatic aluminumSource power 350 wattsAnalysis region 2 mm X 0.8 mmExit angle* 50.degree.Electron acceptance angle .+-.7.degree.Charge neutralization electron flood gunCharge correction C-(C, H) in C 1s spectra at 284.6 eV______________________________________ *Exit angle is defined as the angle between the sample plane and the electron analyzer lens. The silicon photoelectron binding energy was used to characterized the nature of the formed species within the mineralized layer that was formed on the cathode. This species was identified as a zinc disilicate modified by the presence of sodium ion by the binding energy of 102.1 eV for the Si(2 p) photoelectron.

EXAMPLE 2

This Example illustrates performing the inventive electrodeposition process at an increased voltage and current in comparison to Example 1.

Prior to the electrodeposition, the cathode panel was subjected to preconditioning process:

1) 2 minute immersion in a 3:1 dilution of Metal Prep 79 (Parker Amchem), 2) two de-ionized rinse, 3) 10 second immersion in a pH 14 sodium hydroxide solution, 4) remove excess solution and allow to air dry, 5) 5 minute immersion in a 50% hydrogen peroxide solution, 6) Blot to remove excess solution and allow to air dry.

A power supply was connected to an electrodeposition cell consisting of a plastic cup containing two standard ACT cold roll steel (clean, unpolished) test panels. One end of the test panel was immersed in a solution consisting of 10% N grade sodium mineral (PQ Corp.) in de-ionized water. The immersed area (1 side) of each panel was approximately 3 inches by 4 inches (12 sq. in.) for a 1:1 anode to cathode ratio. The panels were connected directly to the DC power supply and a voltage of 6 volts was applied for 1 hour. The resulting current ranged from approximately 0.7-1.9 Amperes. The resultant current density ranged from 0.05-0.16 amps/in.sup.2.

After the electrolytic process, the coated panel was allowed to dry at ambient conditions and then evaluated for humidity resistance in accordance with ASTM Test No. D2247 by visually monitoring the corrosion activity until development of red corrosion upon 5% of the panel surface area. The coated test panels lasted 25 hours until the first appearance of red corrosion and 120 hours until 5% red corrosion. In comparison, conventional iron and zinc phosphated steel panels develop first corrosion and 5% red corrosion after 7 hours in ASTM D2247 humidity exposure. The above Examples, therefore, illustrate that the inventive process offers an improvement in corrosion resistance over iron and zinc phosphated steel panels.

EXAMPLE 3

Two lead panels were prepared from commercial lead sheathing and cleaned in 6M HCl for 25 minutes. The cleaned lead panels were subsequently placed in a solution comprising 1 wt. % N-grade sodium silicate (supplied by PQ Corporation).

One lead panel was connected to a DC power supply as the anode and the other was a cathode. A potentional of 20 volts was applied initially to produce a current ranging from 0.9 to 1.3 Amperes. After approximately 75 minutes the panels were removed from the sodium silicate solution and rinsed with de-ionized water.

ESCA analysis was performed on the lead surface. The silicon photoelectron binding energy was used to characterized the nature of the formed species within the mineralized layer. This species was identified as a lead disilicate modified by the presence of sodium ion by the binding energy of 102.0 eV for the Si(2 p) photoelectron.

EXAMPLE 4

This Example demonstrates forming a mineral surface upon an aluminum substrate. Using the same apparatus in Example 1, aluminum coupons (3".times.6") were reacted to form the metal silicate surface. Two different alloys of aluminum were used, Al 2024 and Al 7075. Prior to the panels being subjected to the electrolytic process, each panel was prepared using the methods outlined below in Table A. Each panel was washed with reagent alcohol to remove any excessive dirt and oils. The panels were either cleaned with Alumiprep 33, subjected to anodic cleaning or both. Both forms of cleaning are designed to remove excess aluminum oxides. Anodic cleaning was accomplished by placing the working panel as an anode into an aqueous solution containing 5% NaOH, 2.4% Na.sub.2 CO.sub.3, 2% Na.sub.2 SiO.sub.3, 0.6% Na.sub.3 PO.sub.4, and applying a potential to maintain a current density of 100 mA/cm.sup.2 across the immersed area of the panel for one minute.

Once the panel was cleaned, it was placed in a 1 liter beaker filled with 800 mL of solution. The baths were prepared using de-ionized water and the contents are shown in the table below. The panel was attached to the negative lead of a DC power supply by a wire while another panel was attached to the positive lead. The two panels were spaced 2 inches apart from each other. The potential was set to the voltage shown on the table and the cell was run for one hour.

TABLE A______________________________________Example A B C D E F G H______________________________________Alloy type 2024 2024 2024 2024 7075 7075 7075 7075Anodic Yes Yes No No Yes Yes No NoCleaningAcid Wash Yes Yes Yes Yes Yes Yes Yes YesBath SolutionNa.sub.2 SiO.sub.3 1% 10% 1% 10% 1% 10% 1% 10%H.sub.2 O.sub.2 1% 0% 0% 1% 1% 0% 0%Potential 12 V 18 V 12 V 18 V 12 V 18 V 12 V 18 V______________________________________

ESCA was used to analyze the surface of each of the substrates. Every sample measured showed a mixture of silica and metal silicate. Without wishing to be bound by any theory or explanation, it is believed that the metal silicate is a result of the reaction between the metal cations of the surface and the alkali silicates of the coating. It is also believed that the silica is a result of either excess silicates from the reaction or precipitated silica from the coating removal process. The metal silicate is indicated by a Si (2 p) binding energy (BE) in the low 102 eV range, typically between 102.1 to 102.3. The silica can be seen by Si(2 p) BE between 103.3 to 103.6 eV. The resulting spectra show overlapping peaks, upon deconvolution reveal binding energies in the ranges representative of metal silicate and silica.

EXAMPLE 5

This Example illustrates an alternative to immersion for creating the silicate containing medium.

An aqueous gel made by blending 5% sodium silicate and 10% fumed silica was used to coat cold rolled steel panels. One panel was washed with reagent alcohol, while the other panel was washed in a phosphoric acid based metal prep, followed by a sodium hydroxide wash and a hydrogen peroxide bath. The apparatus was set up using a DC power supply connecting the positive lead to the steel panel and the negative lead to a platinum wire wrapped with glass wool. This setup was designed to simulate a brush plating operation. The "brush" was immersed in the gel solution to allow for complete saturation. The potential was set for 12 V and the gel was painted onto the panel with the brush. As the brush passed over the surface of the panel, hydrogen gas evolution could be seen. The gel was brushed on for five minutes and the panel was then washed with de-ionized water to remove any excess gel and unreacted silicates.

ESCA was used to analyze the surface of each steel panel. ESCA detects the reaction products between the metal substrate and the environment created by the electrolytic process. Every sample measured showed a mixture of silica and metal silicate. The metal silicate is a result of the reaction between the metal cations of the surface and the alkali silicates of the coating. The silica is a result of either excess silicates from the reaction or precipitated silica from the coating removal process. The metal silicate is indicated by a Si (2 p) binding energy (BE) in the low 102 eV range, typically between 102.1 to 102.3. The silica can be seen by Si(2 p) BE between 103.3 to 103.6 eV. The resulting spectra show overlapping peaks, upon deconvolution reveal binding energies in the ranges representative of metal silicate and silica.

EXAMPLE 6

Using the same apparatus described in Example 1, cold rolled steel coupons (ACT laboratories) were reacted to form the metal silicate surface. Prior to the panels being subjected to the electrolytic process, each panel was prepared using the methods outlined below in Table B. Each panel was washed with reagent alcohol to remove any excessive dirt and oils. The panels were either cleaned with Metalprep 79 (Parker Amchem), subjected to anodic cleaning or both. Both forms of cleaning are designed to remove excess metal oxides. Anodic cleaning was accomplished by placing the working panel as an anode into an aqueous solution containing 5% NaOH, 2.4% Na.sub.2 CO.sub.3, 2% Na.sub.2 SiO.sub.3, 0.6% Na.sub.3 PO.sub.4, and applying a potential to maintain a current density of 100 mA/cm.sup.2 across the immersed area of the panel for one minute.

Once the panel was cleaned, it was placed in a 1 liter beaker filled with 800 mL of solution. The baths were prepared using de-ionized water and the contents are shown in the table below. The panel was attached to the negative lead of a DC power supply by a wire while another panel was attached to the positive lead. The two panels were spaced 2 inches apart from each other. The potential was set to the voltage shown on the table and the cell was run for one hour.

TABLE B______________________________________Example AA BB CC DD EE______________________________________Substrate type CRS CRS CRS CRS.sup.1 CRS.sup.2Anodic Cleaning No Yes No No NoAcid Wash Yes Yes Yes No NoBath SolutionNa.sub.2 SiO.sub.3 1% 10% 1% -- --Potential (V) 14-24 6 (CV) 12 V -- -- (CV)Current Density 23 (CC) 23-10 85-48 -- --(mA/cm.sup.2)B177 2 hrs 1 hr 1 hr 0.25 hr 0.25 hr______________________________________ .sup.1 Cold Rolled Steel Control--No treatment was done to this panel. .sup.2 Cold Rolled Steel with iron phosphate treatment (ACT Laboratories)--No further treatments were performed

The electrolytic process was either run as a constant current or constant voltage experiment, designated by the CV or CC symbol in the table. Constant Voltage experiments applied a constant potential to the cell allowing the current to fluctuate while Constant Current experiments held the current by adjusting the potential. Panels were tested for corrosion protection using ASTM B117. Failures were determined at 5% surface coverage of red rust.

ESCA was used to analyze the surface of each of the substrates. ESCA detects the reaction products between the metal substrate and the environment created by the electrolytic process. Every sample measured showed a mixture of silica and metal silicate. The metal silicate is a result of the reaction between the metal cations of the surface and the alkali silicates of the coating. The silica is a result of either excess silicates from the reaction or precipitated silica from the coating removal process. The metal silicate is indicated by a Si (2 p) binding energy (BE) in the low 102 eV range, typically between 102.1 to 102.3. The silica can be seen by Si(2 p) BE between 103.3 to 103.6 eV. The resulting spectra show overlapping peaks, upon deconvolution reveal binding energies in the ranges representative of metal silicate and silica.

EXAMPLE 7

Using the same apparatus as described in Example 1, zinc galvanized steel coupons (EZG 60G ACT Laboratories) were reacted to form the metal silicate surface. Prior to the panels being subjected to the electrolytic process, each panel was prepared using the methods outlined below in Table C. Each panel was washed with reagent alcohol to remove any excessive dirt and oils.

Once the panel was cleaned, it was placed in a 1 liter beaker filled with 800 mL of solution. The baths were prepared using de-ionized water and the contents are shown in the table below. The panel was attached to the negative lead of a DC power supply by a wire while another panel was attached to the positive lead. The two panels were spaced approximately 2 inches apart from each other. The potential was set to the voltage shown on the table and the cell was run for one hour.

TABLE C______________________________________Example A1 B2 C3 D5______________________________________Substrate type GS GS GS GS.sup.1Bath SolutionNa.sub.2 SiO.sub.3 10% 1% 10% --Potential (V) 6 (CV) 10 (CV) 18 (CV) --Current Density 22-3 7-3 142-3 --(mA/cm.sup.2)B177 336 hrs 224 hrs 216 hrs 96 hrs______________________________________ .sup.1 Galvanized Steel Control--No treatment was done to this panel.

Panels were tested for corrosion protection using ASTM B117. Failures were determined at 5% surface coverage of red rust.

ESCA was used to analyze the surface of each of the substrates. ESCA detects the reaction products between the metal substrate and the environment created by the electrolytic process. Every sample measured showed a mixture of silica and metal silicate. The metal silicate is a result of the reaction between the metal cations of the surface and the alkali silicates of the coating. The silica is a result of either excess silicates from the reaction or precipitated silica from the coating removal process. The metal silicate is indicated by a Si (2 p) binding energy (BE) in the low 102 eV range, typically between 102.1 to 102.3. The silica can be seen by Si(2 p) BE between 103.3 to 103.6 eV. The resulting spectra show overlapping peaks, upon deconvolution reveal binding energies in the ranges representative of metal silicate and silica.

EXAMPLE 8

Using the same apparatus as described in Example 1, copper coupons (C110 Hard, Fullerton Metals) were reacted to form the mineralized surface. Prior to the panels being subjected to the electrolytic process, each panel was prepared using the methods outlined below in Table D. Each panel was washed with reagent alcohol to remove any excessive dirt and oils.

Once the panel was cleaned, it was placed in a 1 liter beaker filled with 800 mL of solution. The baths were prepared using de-ionized water and the contents are shown in the table below. The panel was attached to the negative lead of a DC power supply by a wire while another panel was attached to the positive lead. The two panels were spaced 2 inches apart from each other. The potential was set to the voltage shown on the table and the cell was run for one hour.

TABLE D______________________________________Example AA1 BB2 CC3 DD4 EE5______________________________________Substrate type Cu Cu Cu Cu Cu.sup.1Bath SolutionNa.sub.2 SiO.sub.3 10% 10% 1% 1% --Potential (V) 12 (CV) 6 (CV) 6 (CV) 36 (CV) --Current Density 40-17 19-9 4-1 36-10 --(mA/cm.sup.2)B117 11 hrs 11 hrs 5 hrs 5 hrs 2 hrs______________________________________ .sup.1 Copper Control--No treatment was done to this panel.

Panels were tested for corrosion protection using ASTM B117. Failures were determined by the presence of copper oxide which was indicated by the appearance of a dull haze over the surface.

ESCA was used to analyze the surface of each of the substrates. ESCA allows us to examine the reaction products between the metal substrate and the environment set up from the electrolytic process. Every sample measured showed a mixture of silica and metal silicate. The metal silicate is a result of the reaction between the metal cations of the surface and the alkali silicates of the coating. The silica is a result of either excess silicates from the reaction or precipitated silica from the coating removal process. The metal silicate is indicated by a Si (2 p) binding energy (BE) in the low 102 eV range, typically between 102.1 to 102.3. The silica can be seen by Si(2 p) BE between 103.3 to 103.6 eV. The resulting spectra show overlapping peaks, upon deconvolution reveal binding energies in the ranges representative of metal silicate and silica.

EXAMPLE 9

An electrochemical cell was set up using a 1 liter beaker. The beaker was filled with a sodium silicate solution comprising 10 wt % N sodium silicate solution (PQ Corp). The temperature of the solution was adjusted by placing the beaker into a water bath to control the temperature. Cold rolled steel coupons (ACT labs, 3.times.6 inches) were used as anode and cathode materials. The panels are placed into the beaker spaced 1 inch apart facing each other. The working piece was established as the anode. The anode and cathode are connected to a DC power source. The table below shows the voltages, solutions used, time of electrolysis, current density, temperature and corrosion performance.

TABLE E______________________________________ Silicate Bath Current Bath CorrosionSample Conc. Temp Voltage Density Time Hours# Wt % .degree. C. Volts mA/cm.sup.2 min. (B117)______________________________________I-A 10% 24 12 44-48 5 1I-B 10% 24 12 49-55 5 2I-C 10% 37 12 48-60 30 71I-D 10% 39 12 53-68 30 5I-F 10% 67 12 68-56 60 2I-G 10% 64 12 70-51 60 75I-H NA NA NA NA NA 0.5______________________________________ The panels were rinsed with de-ionized water to remove any excess silicates that may have been drawn from the bath solution. The panels underwent corrosion testing according to ASTM B117. The time it took for the panels to reach 5% red rust coverage (as determined by visual observation) in the corrosion chamber was recorded as shown in the above table. Example I-H shows the corrosion results of the same steel panel that did not undergo any treatment.

EXAMPLE 10

Examples 10, 11, and 14 demonstrate one particular aspect of the invention, namely, imparting corrosion resistance to steel shafts that are incorporated within electric motors. The motor shafts were obtained from Emerson Electric Co. from St. Louis, Mo. and are used to hold the rotor assemblies. The shafts measure 25 cm in length and 1.5 cm in diameter and are made from commercially available steel.

An electrochemical cell was set up similar to that in Example 9; except that the cell was arranged to hold the previously described steel motor shaft. The shaft was set up as the cathode while two cold rolled steel panels were used as anodes arranged so that each panel was placed on opposite sides of the shaft. The voltage and temperature were adjusted as shown in the following table. Also shown in the table is the current density of the anodes

TABLE F______________________________________ Silicate Bath Current BathSample Conc. Temp Voltage Density Time Corrosion# Wt % .degree. C. Volts mA/cm.sup.2 min. Hours______________________________________II-A 10% 27 6 17-9 60 3II-B 10% 60 12 47-35 60 7II-C 10% 75 12 59-45 60 19II-D 10% 93 12 99-63 60 24II-F 10% 96 18 90-59 60 24II-G NA NA NA NA NA 2II-H NA NA NA NA NA 3______________________________________ The shafts were rinsed with de-ionized water to remove any excess silicates that may have been drawn from the bath solution. Example II-A showed no significant color change compared to Examples II-B-II-F due to the treatment. Example II-B showed a slight yellow/gold tint. Example II-C showed a light blue and slightly pearlescent color. Example II-D and II- showed a darker blue color due to the treatment. The panels underwent corrosion testing according to ASTM B117. The time it took for the shafts to reach 5% red rust coverage in the corrosion chamber was recorded as shown in the table. Example II-G shows the corrosion results of the same steel shaft that did not undergo any treatment and Example II-H shows the corrosion results of the same steel shaft with a commercial zinc phosphate coating.

EXAMPLE 11

An electrochemical cell was set up similar to that in Example 10 to treat steel shafts. The motor shafts were obtained from Emerson Electric Co. of St. Louis, Mo. and are used to hold the rotor assemblies. The shafts measure 25 cm in length and 1.5 cm in diameter and are made from commercially available steel. The shaft was set up as the cathode while two cold rolled steel panels were used as anodes arranged so that each panel was placed on opposite sides of the shaft. The voltage and temperature were adjusted as shown in the following table. Also shown in the table is the current density of the anodes

TABLE G______________________________________ Silicate Bath Current BathSample Conc. Temp Voltage Density Time Corrosion# Wt % .degree. C. Volts mA/cm.sup.2 min. Hours______________________________________III-A 10% 92 12 90-56 60 504III-B 10% 73 12 50-44 60 552III-C NA NA NA NA NA 3III-D NA NA NA NA NA 3______________________________________ The shafts were rinsed with de-ionized water to remove any excess silicates that may have been drawn from the bath solution. The panels underwent corrosion testing according to ASTM D2247. The time it too for the shafts to reach 5% red rust coverage in the corrosion chamber was recorded as shown in the table. Example III-C shows the corrosion results of the same steel shaft that did not undergo any treatment and Example III-D shows the corrosion results of the same steel shaft with a commercial zinc phosphate coating.

EXAMPLE 12

An electrochemical cell was set up using a 1 liter beaker. The solution was filled with sodium silicate solution comprising 5,10, or 15 wt % of N sodium silicate solution (PQ Corporation). The temperature of the solution was adjusted by placing the beaker into a water bath to control the temperature. Cold rolled steel coupons (ACT labs, 3.times.6 inches) were used as anode and cathode materials. The panels are placed into the beaker spaced 1 inch apart facing each other. The working piece is set up as the anode. The anode and cathode are connected to a DC power source. The table below shows the voltages, solutions used, time of electrolysis, current density through the cathode, temperature, anode to cathode size ratio, and corrosion performance.

TABLE H______________________________________ Silicate Bath Current BathSample Conc. Temp Voltage Density A/C Time Corrosion# Wt % .degree. C. Volts mA/cm.sup.2 ratio Min. Hours______________________________________IV-1 5 55 12 49-51 0.5 15 2IV-2 5 55 18 107-90 2 45 1IV-3 5 55 24 111-122 1 30 4IV-4 5 75 12 86-52 2 45 2IV-5 5 75 18 111-112 1 30 3IV-6 5 75 24 140-134 0.5 15 2IV-7 5 95 12 83-49 1 30 1IV-8 5 95 18 129-69 0.5 15 1IV-9 5 95 24 196-120 2 45 4IV-10 10 55 12 101-53 2 30 3IV-11 10 55 18 146-27 1 15 4IV-12 10 55 24 252-186 0.5 45 7IV-13 10 75 12 108-36 1 15 4IV-14 10 75 18 212-163 0.5 45 4IV-15 10 75 24 248-90 2 30 16IV-16 10 95 12 168-161 0.5 45 4IV-17 10 95 18 257-95 2 30 6IV-18 10 95 24 273-75 1 15 4IV-19 15 55 12 140-103 1 45 4IV-20 15 55 18 202-87 0.5 30 4IV-21 15 55 24 215-31 2 15 17IV-22 15 75 12 174-86 0.5 30 17IV-23 15 75 18 192-47 2 15 15IV-24 15 75 24 273-251 1 45 4IV-25 15 95 12 183-75 2 15 8IV-26 15 95 18 273-212 1 45 4IV-27 15 95 24 273-199 0.5 30 15IV-28 NA NA NA NA NA NA 0.5______________________________________ The panels were rinsed with de-ionized water to remove any excess silicates that may have been drawn from the bath solution. The panels underwent corrosion testing according to ASTM B117. The time it took for the panels to reach 5% red rust coverage in the corrosion chamber was recorded as shown in the table. Example IV-28 shows the corrosion results of the same steel panel that did not undergo any treatment. The table above shows the that corrosion performance increases with silicate concentration in the bath and elevated temperatures. Corrosion protection can also be achieved within 15 minutes. With a higher current density, the corrosion performance can be enhanced further.

EXAMPLE 13

An electrochemical cell was set up using a 1 liter beaker. The solution was filled with sodium silicate solution comprising 10 wt % N sodium silicate solution (PQ Corporation). The temperature of the solution was adjusted by placing the beaker into a water bath to control the temperature. Zinc galvanized steel coupons (ACT labs, 3.times.6 inches) were used as cathode materials. Plates of zinc were used as anode material. The panels are placed into the beaker spaced 1 inch apart facing each other. The working piece was set up as the anode. The anode and cathode are connected to a DC power source. The table below shows the voltages, solutions used, time of electrolysis, current density, and corrosion performance.

TABLE I______________________________________ Silicate Current BathSample Conc. Voltage Density Time Corrosion Corrosion# Wt % Volts mA/cm.sup.2 min. (W) Hours (R) Hours______________________________________V-A 10% 6 33-1 60 16 168V-B 10% 3 6.5-1 60 17 168V-C 10% 18 107-8 60 22 276V-D 10% 24 260-7 60 24 276V-E NA NA NA NA 10 72______________________________________ The panels were rinsed with de-ionized water to remove any excess silicates that may have been drawn from the bath solution. The panels underwent corrosion testing according to ASTM B117. The time when the panels showed indications of pitting and zinc oxide formation is shown as Corrosion (W). The time it took for the panels to reach 5% red rust coverage in the corrosion chamber was recorded as shown in the table as Corrosion (R). Example V-E shows the corrosion results of the same steel panel that did not undergo any treatment.

EXAMPLE 14

An electrochemical cell was set up similar to that in Examples 10-12 to treat steel shafts. The motor shafts were obtained from Emerson Electric Co. of St. Louis, Mo. and are used to hold the rotor assemblies. The shafts measure 25 cm in length and 1.5 cm in diameter and the alloy information is shown below in the table. The shaft was set up as the cathode while two cold rolled steel panels were used as anodes arranged so that each panel was placed on opposite sides of the shaft. The voltage and temperature were adjusted as shown in the following table. Also shown in the table is the current density of the anodes

TABLE J______________________________________ Silicate Bath Current Bath Conc. Temp Voltage Density Time Corrosion# Alloy Wt % .degree. C. Volts mA/cm.sup.2 min. Hours______________________________________VI-A 1018 10% 75 12 94-66 30 16VI-B 1018 10% 95 18 136-94 30 35VI-C 1144 10% 75 12 109-75 30 9VI-D 1144 10% 95 18 136-102 30 35VI-F 1215 10% 75 12 92-52 30 16VI-G 1215 10% 95 18 136-107 30 40______________________________________ The shafts were rinsed with de-ionized water to remove any excess silicates that may have been drawn from the bath solution. The panels underwent corrosion testing according to ASTM B117. The time it took for the shafts to reach 5% red rust coverage in the corrosion chamber was recorded as shown in the table.

EXAMPLE 15

This Example illustrates using an electrolytic method to form a mineral surface upon steel fibers that can be pressed into a finished article or shaped into a preform that is infiltrated by another material.

Fibers were cut (0.20-0.26 in) from 1070 carbon steel wire, 0.026 in. diameter, cold drawn to 260,000-280,000 PSI. 20 grams of the fibers were placed in a 120 mL plastic beaker. A platinum wire was placed into the beaker making contact with the steel fibers. A steel square 1 in by 1 in, was held 1 inch over the steel fibers, and supported so not to contact the platinum wire. 75 ml of 10% solution of sodium silicate (N-Grade PQ corp) in deionized water was introduced into the beaker thereby immersing both the steel square and the steel fibers and forming an electrolytic cell. A 12 V DC power supply was attached to this cell making the steel fibers the cathode and steel square the anode, and delivered an anodic current density of up to about 3 Amps/sq. inch. The cell was placed onto a Vortex agitator to allow constant movement of the steel fibers. The power supply was turned on and a potential of 12 V passed through the cell for 5 minutes. After this time, the cell was disassembled and the excess solution was poured out, leaving behind only the steel fibers. While being agitated, warm air was blown over the steel particles to allow them to dry.

Salt spray testing in accordance with ASTM B-117 was performed on these fibers. The following table lists the visually determined results of the ASTM B-117 testing.

TABLE K______________________________________Treatment 1.sup.st onset of corrosion 5% red coverage______________________________________UnCoated 1 hour 5 hoursElectrolytic 24 hours 60______________________________________

EXAMPLES 16-24

The inventive process demonstrated in Examples 16-24 utilized a 1 liter beaker and a DC power supply as described in Example 2. The silicate concentration in the bath, the applied potential and bath temperature have been adjusted and have been designated by table L-A.

TABLE L-A______________________________________Process silicate conc. Potential Temperature Time______________________________________A 1 wt. % 6 V 25 C. 30 minB 10% 12 V 75 C. 30 minC 15% 12 V 25 C. 30 minD 15% 18 V 75 C. 30 min______________________________________

EXAMPLE 16

To test the effect of metal ions in the electrolytic solutions, iron chloride was added to the bath solution in concentrations specified in the table below. Introducing iron into the solution was difficult due to its tendency to complex with the silicate or precipitate as iron hydroxide. Additions of iron was also limited due to the acidic nature of the iron cation disrupting the solubility of silica in the alkaline solution. However, it was found that low concentrations of iron chloride (<0.5%) could be added to a 20% N silicate solution in limited quantities for concentrations less that 0.025 wt % FeCl3 in a 10 wt % silicate solution. Table L shows a matrix comparing electrolytic solutions while keeping other conditions constant. Using an inert anode, the effect of the solution without the effect of any anion dissolution were compared.

TABLE L-B______________________________________ Silicate Iron 1st FailureProcess conc (%) Conc (%) Anode Red (5% red)______________________________________B 10% 0 Pt 2 hrs 3 hrsB 10 0.0025 Pt 2 hrs 3 hrsB 10 0.025 Pt 3 hrs 7 hrsB 10 0 Fe 3 hrs 7 hrsB 10 0.0025 Fe 2 hrs 4 hrsB 10 0.025 Fe 3 hrs 8 hrsControl N/A N/A N/A 1 hr 1 hrControl N/A N/A N/A 1 hr 1 hr______________________________________ Table L-B Results showing the inventive process at 12 V for 30 minutes at 75 C. in a 10% silicate solution. Anodes used are either a platinum net or an iron panel. The solution is a 10% silicate solution with 0-0.0025% iron chloride solution. Corrosion performance is measured in ASTM B117 exposure time.

The trend shows increasing amounts of iron doped into the bath solution using an inert platinum electrode will perform similarly to a bath without doped iron, using an iron anode. This Example demonstrates that the iron being introduced by the steel anode, which provides enhanced corrosion resistance, can be replicated by the introduction of an iron salt solution.

EXAMPLE 17

Without wishing to be bound by any theory or explanation, it is believed that the mineralization reaction mechanism includes a condensation reaction. The presence of a condensation reaction can be illustrated by a rinse study wherein the test panel is rinsed after the electrolytic treatment shown in Table M-A. Table M-A illustrates that corrosion times increase as the time to rinse also increases. It is believed that if the mineral layer inadequately cross-links or polymerizes within the mineral layer the mineral layer can be easily removed in a water rinse. Conversely, as the test panel is dried for a relatively long period of time, the corrosion failure time improves thereby indicating that a fully crossed-linked or polymerized mineral layer was formed. This would further suggest the possibility of a further reaction stage such as the cross-linking reaction.

The corrosion resistance of the mineral layer can be enhanced by heating. Table M-B shows the effect of heating on corrosion performance. The performance begins to decline after about 600 F. Without wishing to be bound by any theory or explanation, it is believed that the heating initially improves cross-linking and continued heating at elevated temperatures caused the cross-linked layer to degrade.

TABLE M-A______________________________________Time of rinse Failure time______________________________________Immediately after process--still wet 1 hourImmediately after panel dries 2 hour1 hour after panel dries 5 hour24 hours after panel dries 7 hour______________________________________ Table M-A- table showing corrosion failure time (ASTM B117) for steel test panel, treated with the CEM silicate, after being rinsed at different times after treatment. TABLE M-B______________________________________Process Heat Failure______________________________________B 72 F. 2 hrsB 200 F. 4 hrsB 300 F. 4 hrsB 400 F. 4 hrsB 500 F. 4 hrsB 600 F. 4 hrsB 700 F. 2 hrsB 800 F. 1 hr.sup.D 72 F. 3 hrsD 200 F. 5 hrsD 300 F. 6 hrsD 400 F. 7 hrsD 500 F. 7 hrsD 600 F. 7 hrsD 700 F. 4 hrsD 800 F. 2 hrs______________________________________ Table M-B- CEM treatment on steel substrates. Process B refers to a 12 V, 30 minute cathodic mineralization treatment in a 10% silicate solution. Process D refers to a 18 V, 30 minute, cathodic mineralization treatment in a 15% silicate solution. The failure refers to time to 5% red rust coverage in an ASTM B117 salt spray environment.

EXAMPLE 18

In this Example the binding energy of a mineral layer formed on stainless steel is analyized. The stainless steel was a ANSI 304 alloy. The samples were solvent washed and treated using Process B (a 10% silicate solution doped with iron chloride, at 75 C at 12 V for 30 minutes). ESCA was performed on these treated samples in accordance with conventional methods. The ESCA results showed an Si(2 p) binding energy at 103.4 eV.

The mineral surface was also analyized by using Atomic Force Microscope (AFM). The surface revealed crystals were approximately 0.1 to 0.5 .mu.m wide.

EXAMPLE 19

The mineral layer formed in accordance with Example 18--method B was analyzed by using Auger Electron Spectroscopy (AES) in accordance with conventional testing methods. The approximate thickness of the silicate layer was determined to be about 5000 angstroms (500 nm) based upon silicon, metal, and oxygen levels. The silica layer was less than about 500 angstroms (50 nm) based on the levels of metal relative to the amount of silicon and oxygen.

The mineral layer formed in accordance with Example 16 method B applied on a ANSI 304 stainless steel substrate. The mineral layer was analyzed using Atomic Force Microscopy (AFM) in accordance to conventional testing methods. AFM revealed the growth of metal silicate crystals (approximately 0.5 microns) clustered around the areas of the grain boundaries. AFM analysis of mineral layers of steel or zinc substrate did not show this similar growth feature.

EXAMPLE 20

This Example illustrates the affect of silicate concentration on the inventive process. The concentration of the electrolytic solution can be depleted of silicate after performing the inventive process. A 1 liter 10% sodium silicate solution was used in an experiment to test the number of processes a bath could undergo before the reducing the effectiveness of the bath. After 30 uses of the bath, using test panels exposing 15 in.sup.2, the corrosion performance of the treated panels decreased significantly.

Exposure of the sodium silicates to acids or metals can gel the silicate rendering it insoluble. If a certain minimum concentration of silicate is available, the addition of an acid or metal salt will precipitate out a gel. If the solution is depleted of silicate, or does not have a sufficient amount, no precipitate should form. A variety of acids and metal salts were added to aliquots of an electrolytic bath. After 40 runs of the inventive process in the same bath, the mineral barrier did not impart the same level of protection. This Example illustrates that iron chloride and zinc chloride can be employed to test the silicate bath for effectiveness.

TABLE N______________________________________ Run Run Run RunSolution Run 0 10 20 30 40______________________________________0.1% FeCl3 2 drops - - - - - 10 drops + Trace Trace trace trace 1 mL + + + + trace10% FeCl3 2 drops + + + + + 10 drops Thick Thick Thick not as not as thick thick0.05% ZnSO4 2 drops - - - - - 10 drops - - - - -5% ZnSO4 2 drops + + + + + 10 drops + + + + finer0.1% ZnCl2 2 drops + + + + - 10 drops + + + + not as thick10% ZnCl2 2 drops + + + + finer 10 drops + + + + +0.1% HCl 2 drops - - - - - 10 drops - - - - -10% HCl 2 drops - - - - - 10 drops - - - - -0.1% K3Fe(CN)6 2 drops - - - - - 10 drops - - - - -10% K3Fe(CN)6 2 drops - - - - - 10 drops - - - - -______________________________________ Table N--A 50 ml sample of bath solution was taken every 5th run and tested using a ppt test. A "-" indicates no precipitation. a "+" indicates the formation of a precipitate.

EXAMPLE 21

This Example compares the corrosion resistance of a mineral layer formed in accordance with Example 16 on a zinc containing surface in comparison to an iron (steel) containing surface. Table O shows a matrix comparing iron (cold rolled steel-CRS) and zinc (electrogalzanized zinc-EZG) as lattice building materials on a cold rolled steel substrate and an electrozinc galvanized substrate. The results comparing rinsing are also included on Table O. Comparing only the rinsed samples, greater corrosion resistance is obtained by employing differing anode materials. The Process B on steel panels using iron anions provides enhanced resistance to salt spray in comparison to the zinc materials.

TABLE O______________________________________Substrate Anode Treatment Rinse 1st White 1st Red Failure______________________________________CRS Fe B None 1 2CRS Fe B DI 3 24CRS Zn B None 1CRS Zn B DI 2 5EZG Zn B None 1 240 582EZG Zn B DI 1 312 1080EZG Fe B None 1 312 576EZG Fe B DI 24 312 864CRS Control Control None 2 2EZG Control Control None 3 168 192______________________________________ Table O--Results showing ASTM B117 corrosion results for cathodic mineralization treated cold rolled steel and electrozinc galvanized steel panels using different anode materials to build the mineral lattice.

EXAMPLE 22

This Example illustrates using a secondary layer upon the mineral layer in order to provide further protection from corrosion (a secondary layer typically comprises compounds that have hydrophilic components which can bind to the mineral layer).

The electronic motor shafts that were mineralized in accordance with Example 10 were contacted with a secondary coating. The two coatings which were used in the shaft coatings were tetra-ethyl-ortho-silicate (TEOS) or an organofunctional silane (VS). The affects of heating the secondary coating are also listed in Table P-A and P-B. Table P-A and P-B show the effect of TEOS and vinyl silanes on the inventive B Process.

TABLE P-A______________________________________Treat- TEOS 150 C.ment ED Time Dry Rinse Dip Heat 1st Red Failure______________________________________B 10 min None No No no 3 hrs 5 hrsB 10 min None No No yes 7 hrs 10 hrsB 30 min None No No no 3 hrs 5 hrsB 30 min None No No yes 6 hrs 11 hrsB 10 min Yes No Yes no 3 hrs 3 hrsB 30 min Yes No Yes yes 3 hrs 4 hrsB 10 min 1 hr No Yes no 1 hr 3 hrsB 10 min 1 hr No Yes yes 7 hrs 15 hrsB 10 min 1 hr Yes Yes no 5 hrs 6 hrsB 10 min 1 hr Yes Yes yes 3 hrs 4 hrsB 10 min 1 day No Yes no 3 hrs 10 hrsB 10 min 1 day No Yes yes 3 hrs 17 hrsB 10 min 1 day Yes Yes no 4 hrs 6 hrsB 10 min 1 day Yes Yes yes 3 hrs 7 hrsB 30 min 1 hr No Yes no 6 hrs 13 hrsB 30 min 1 hr No Yes yes 6 hrs 15 hrsB 30 min 1 hr Yes Yes no 3 hrs 7 hrsB 30 min 1 hr Yes Yes yes 2 hrs 6 hrsB 30 min 1 day No Yes no 6 hrs 10 hrsB 30 min 1 day No Yes yes 6 hrs 18 hrsB 30 min 1 day Yes Yes no 6 hrs 6 hrsB 30 min 1 day Yes Yes yes 4 hrs 7 hrsControl 0 0 No No No 5 hrs 5 hrsControl 0 0 No No No 5 hrs 5 hrs______________________________________ Table P-A--table showing performance effects of TEOS and heat on the B Process. TABLE P-B______________________________________Treatment Rinse Bake Test 1st Red Failure______________________________________B DI No Salt 3 10B DI 150 c Salt 3 6B A151 No Salt 4 10B A151 150 c Salt 2 10B A186 No Salt 4 12B A186 150 c Salt 1 7B A187 No Salt 2 16B A187 150 c Salt 2 16Control None None Salt 1 1______________________________________ DI = deionized water A151 = vinyltriethoxysilane (Witco) A186 = Beta(3,4-epoxycylcohexyl)-ethyltrimethoxysilane (Witco) A187 = Gammaglycidoxypropyltrimethoxysilane (Witco) Table P-B--Table showing the effects of vinyl silanes on Elisha B treatment

Table P-A illustrates that heat treating improves corrosion resistance. The results also show that the deposition time can be shortened if used in conjunction with the TEOS. TEOS and heat application show a 100% improvement over standard Process B. The use of vinyl silane also is shown to improve the performance of the Process B. One of the added benefits of the organic coating is that it significantly reduces surface energy and repels water.

EXAMPLE 23

This Example illustrates evaluating the inventive process for forming a coating on bare and galvanized steel was evaluated as a possible phosphate replacement for E-coat systems. The evaluation consisted of four categories: applicability of E-coat over the mineral surface; adhesion of the E-coat; corrosion testing of mineral/E-coat systems; and elemental analysis of the mineral coatings. Four mineral coatings (Process A, B, C, D) were evaluated against phosphate controls. The e-coat consisted of a cathodically applied blocked isocyanate epoxy coating.

TABLE Q______________________________________Process SiO3 conc. Potential Temperature Time______________________________________A 1% 6 V 25 C. 30 minB 10% 12 V 75 C. 30 minC 15% 12 V 25 C. 30 minD 15% 18 V 75 C. 30 min______________________________________

It was found that E-coat could be uniformly applied to the mineral surfaces formed by processes A-D with the best application occuring on the mineral formed with processes A and B. It was also found that the surfaces A and B had no apparent detrimental effect on the E-coat bath or on the E-coat curing process. The adhesion testing showed that surfaces A, B, and D had improved adhesion of the E-coat to a level comparable with that of phosphate. Similar results were seen in surfaces C and D over galvanized steel. Surfaces B and D generally showed more corrosion resistance than the other variations evaluated.

To understand any relation between the coating and performance, elemental analysis was done. It showed that the depth profile of coatings B and D was significant, >5000 angstroms.

EXAMPLE 24

This Example demonstrates the affects of the inventive process on stress corrosion cracking. These tests were conducted to examine the influence of the inventive electrolytic treatments on the susceptibility of AISI 304 stainless steel coupons to stress cracking. The tests revealed improvement in pitting resistance for samples following the inventive process. Four corrosion coupons of AISI 304 stainless steel were used in the test program. One specimen was tested without surface treatment. Another specimen was tested following an electrolytic treatment of Example 16, method B.

The test specimens were exposed according to ASTM G48 Method A (Ferric Chloride Pitting Test). These tests consisted of exposures to a ferric chloride solution (about 6 percent by weight) at room temperature for a period of 72 hours.

The results of the corrosion tests are given in Table R. The coupon with the electrolytic treatment suffered mainly end grain attack as did the non-treated coupon.

TABLE R__________________________________________________________________________Results of ASTM G48 Pitting TestsMax. Pit Depth Pit Penetration Rate(mils) (mpy) Comments__________________________________________________________________________3.94 479 Largest pits on edges. Smaller pits on surface.__________________________________________________________________________ASTM G-48, 304 stainless steel Exposure to Ferric Chloride,72 Hours, Ambient Temperature WEIGHT WEIGHT AFTER SUR-INITIAL AFTER TEST SCALE WEIGHT FACE DEN- CORR.WEIGHT TEST CLEANED WEIGHT LOSS AREA TIME SITY RATE(g) (g) (g) (g) (g)* (sq. in) (hrs) (g/cc) (mpy)__________________________________________________________________________28,7378 28.2803 28.2702 -0.4575 0.4676 4.75 72.0 7.80 93.663__________________________________________________________________________

EXAMPLE 25

This example illustrates the improved adhesion and corrosion protection of the inventive process as a pretreatment for paint top coats. A mineral layer was formed on a steel panel in accordance to Example 16, process B. The treated panels were immersed in a solution of 5% bis-1,2-(triethoxysilyl) ethane (BSTE-Witco) allowed to dry and then immerse in a 2% solution of vinyltriethoxysilane (Witco) or 2% Gammaglycidoxypropyl-trimethoxysilane (Witco). For purposes of comparison, a steel panel treated only with BSTE followed by vinyl silane, and a zinc phosphate treated steel panel were prepared. All of the panels were powder coated with a thermoset epoxy paint (Corvel 10-1002 by Morton) at a thickness of 2 mils. The panels were scribed using a carbide tip and exposed to ASTM B117 salt spray for 500 hours. After the exposure, the panels were removed and rinsed and allowed to dry for 1 hour. Using a spatula, the scribes were scraped, removing any paint due to undercutting, and the remaining gaps were measured. The zinc phosphate and BSTE treated panels both performed comparably showing an average gap of 23 mm. The mineralized panels with the silane post treatment showed no measurable gap beside the scribe. The mineralized process performed in combination with a silane treatment showed a considerable improvement to the silane treatment alone. This Example demonstrates that the mineral layer provides a surface or layer to which the BSTE layer can better adhere.

Claims

1. An electrically enhanced method for treating an electrically conductive surface comprising:

contacting the surface with an aqueous medium comprising a combination comprising water and at least one water soluble silicate,

establishing an electrolytic environment within the medium wherein the surface is employed as a cathode,

passing a current through said surface and medium at a rate and period of time sufficient to react at least a portion of the surface, and;

applying at least one secondary coating upon the reacted surface.

2. A method for improving the corrosion resistance of a metal containing surface comprising:

immersing the metal surface within an aqueous medium comprising at least one water soluble silicate,

establishing an electrolytic environment within the medium wherein the surface is employed as a cathode,

passing a current through said surface and medium wherein at least a portion of the metal surface reacts with the medium to form a layer having improved corrosion resistance in comparison to the metal surface; and;

applying at least one secondary coating.

3. A cathodic method for forming a mineral coating upon a metal containing or electrically conductive surface comprising:

exposing the surface to an aqueous medium comprising at least one water soluble silicate,

establishing an electrolytic environment within the medium wherein the surface is employed as a cathode,

passing a current through the silicate medium and the surface for a period of time and under conditions sufficient to form a mineral coating upon the metal surface; and

applying at least one secondary coating.

4. The method of any one of claims 1, 2 or 3 wherein the silicate containing medium comprises sodium silicate.

5. The method of any one of claims 1, 2 or 3 wherein the surface comprises at least one member selected from the group consisting of lead, copper, zinc, aluminum, iron, brass, nickel, magnesium and steel.

6. The method of claim 1 wherein the aqueous silicate containing medium comprises sodium silicate, said surface comprises at least one member chosen from the group of steel, stainless steel, iron and zinc; said dopant comprises iron, and said secondary coating comprises at least one of silanes and epoxies.

7. The method of claim 2 wherein the corrosion resistant surface comprises a mineral layer.

8. The method of any one of claims 1, 2 or 3 wherein the medium is substantially chromate and phosphate free.

9. The method of claim 1 wherein the surface has an ASTM B-117 exposure of greater than 2 hours.

10. The method of any one of claims 1, 2 or 3 wherein the medium comprises greater than 3 wt. % of at least one alkali silicate.

11. The method of any one of claims 1, 2 or 3 further comprising forming a layer comprising silica and prior to said applying at least one secondary coating either a) modifying the silica layer, or b) substantially removing the silica layer.

12. The method of any one of claims 1, 2 or 3 wherein said medium is substantially solvent free.

13. The method of any one of claims 1, 2 or 3 wherein the medium comprises at least one member chosen from the group of a fluid bath, gel or spray.

14. The method of any one of claims 1, 2 or 3 wherein the medium further comprises at least one dopant.

15. The method of claim 14 wherein the dopant comprises at least one member selected from the group consisting of tungsten, molybdenum, chromium, titanium, zirconium, fluorine, vanadium, phosphorus, aluminum, iron, boron, bismuth, gallium, tellurium, germanium, antimony, niobium, magnesium, manganese, and their oxides and salts and precursors thereof.

16. The method of any one of claims 1, 2 or 3 wherein the medium further comprises at least one water dispersible polymer.

17. The method of claim 14 wherein the dopant comprises the anode of the electrolytic environment.

18. The method of any one of claims 1, 2 or 3 wherein said secondary coating comprises at least one member chosen from the group of acrylics, urethanes, epoxies and silanes.

19. The method of claim 18 wherein the secondary coating comprises at least one silane.

20. The method of claim 18 wherein the secondary coating comprises at least one epoxy.

21. The method of any one of claims 1, 2 or 3 wherein the secondary coating comprises a first coating comprising at least one silane and a second coating comprising at least one epoxy.

22. The method of claim 5 wherein said surface comprises steel.

23. The method of claim 1 furthering comprising cleaning the surface prior to said contacting.

24. The method of claim 11 wherein said modifying the silica layer comprises chemically modifying the silica layer.

25. The method of any one of claims 1, 2 or 3 further comprising exposing the surface to an acid treatment after passing a current through the surface and prior to applying said at least one secondary coating.

26. The method of claim 11 wherein said dopant comprises at least one water soluble iron dopant.