Method and composition for creation of conversion surface

Abstract

The present invention relates generally to the field of metal conversion surfaces, in particular, the creation of a phosphate-metal chemisorbed layer for iron and aluminum parts as well as to other metal substrates capable of forming a conversion surface. A phosphorus-containing solution is brought into contact with the metal components such that a conversion surface is formed.

What is claimed is:  
     
         1 . A phosphorus-containing solution comprising a mixture of salts and a carrier fluid, the salts comprising: 
 [Y]H 2 PO 4 ; and    [y] 2 HPO 4 , where [Y] is a cation,    the carrier fluid being operable to maintain the salts within the carrier fluid in at least a partially dispersed state, the phosphorus-containing solution being operable to create a phosphate-metal layer on a metal substrate when the phosphorus-containing solution is placed in contact with the metal substrate, the phosphorus-containing solution being essentially free of zinc and the mixture to form the phosphorus-containing solution being mixed in the absence of a highly exothermic reaction.    
     
     
         2 . The phosphorus-containing solution of  claim 1  further comprising [NR 4 ] 2 HPO 4  wherein R is selected from the group consisting of hydrogen, alkyl groups and combinations thereof.  
     
     
         3 . The phosphorus-containing solution of  claim 2  wherein substantially no free ammonia is present.  
     
     
         4 . The phosphorus-containing solution of  claim 1  further comprising [X]C 2 H 3 O 2  where C 2 H 3 O 2  is an acetate group and [α]is a cation.  
     
     
         5 . The phosphorus-containing solution of  claim 4  wherein [X] is selected from the group consisting of potassium, NH 4 , and combinations thereof.  
     
     
         6 . The phosphorus-containing solution of  claim 1  wherein the pH of the phosphorus-containing solution is between about 6.0 and 8.0.  
     
     
         7 . The phosphorus-containing solution of  claim 1  wherein Y in [Y]H 2 PO 4  is potassium.  
     
     
         8 . The phosphorus-containing solution of  claim 1  wherein Y in [Y] 2 HPO 4  is potassium.  
     
     
         9 . The phosphorus-containing solution of  claim 1  wherein Y in [Y]H 2 PO 4  and [Y] 2 HPO 4  is selected from alkali metals.  
     
     
         10 . The phosphorus-containing solution of  claim 1  further comprising a dispersant.  
     
     
         11 . The phosphorus-containing solution of  claim 1  further comprising a target fluid such that the target fluid is operable to bring the phosphorus-containing solution into contact with metal.  
     
     
         12 . The phosphorus-containing solution of  claim 11  wherein the target fluid is a lubricating fluid.  
     
     
         13 . The phosphorus-containing solution of  claim 1  wherein the metal substrate comprises at least part of an engine  
     
     
         14 . A process for creating a phosphate-metal layer on a metal substrate where the metal substrate is in at least partial contact with a target fluid, the process comprising adding an amount of the phosphorus-containing solution of  claim 1  to the target fluid effective to create the phosphate-metal layer, the target fluid combined with the phosphorus-containing solution being brought into contact with the metal substrate such that the phosphate-metal layer results on the metal substrate.  
     
     
         15 . The process of  claim 14  wherein the phosphorus-containing solution further comprises [NR 4 ] 2 HPO 4  wherein R is selected from the group consisting of hydrogen, alkyl groups and combinations thereof.  
     
     
         16 . The process of  claim 15  wherein the phosphorus-containing solution further comprises NH 4 C 2 H 3 O 2  where C 2 H 3 O 2  is an acetate group.  
     
     
         17 . The process of  claim 16  wherein the pH of the phosphorus-containing solution is between about 6.0 and 8.0.  
     
     
         18 . The process of  claim 14  wherein the Y in [Y]H 2 PO 4  in the phosphorus-containing solution is potassium.  
     
     
         19 . The process of  claim 14  wherein the Y in [Y] 2 HPO 4  in the phosphorus-containing solution is potassium.  
     
     
         20 . The process of  claim 14  wherein the target fluid is selected from the group consisting of lubricating fluid or phosphating bath.  
     
     
         21 . A converted metal substrate including a phosphate-metal layer created by the process of  claim 14  forming a conversion surface on a metal substrate.  
     
     
         22 . The converted metal substrate of  claim 21  wherein the metal substrate comprises iron.  
     
     
         23 . The converted metal substrate of  claim 21  wherein the metal substrate comprises a non-ferrous metal.  
     
     
         24 . The converted metal substrate of  claim 23  wherein the non-ferrous metal is aluminum.  
     
     
         25 . The converted metal substrate of  claim 20  wherein the metal substrate is at least part of an engine.  
     
     
         26 . A lubricating composition comprising 
 a substantial amount of an oil having a lubricating viscosity, and an amount of the phosphorus-containing solution of  claim 1  operable to create a phosphate-metal layer upon a metal component upon being brought into contact with the metal component.    
     
     
         27 . The lubricating composition of  claim 26  wherein phosphorus is present in the lubricating composition in an amount of between about 300 ppm and 1250 ppm.  
     
     
         28 . A method of lubricating an internal combustion engine, comprising supplying to the engine the lubricating composition of  claim 26 .  
     
     
         29 . A method of forming a non-ferrous metal-phosphate conversion surface on a non-ferrous metal components, the method comprising the steps of: 
 preparing an active phosphorus solution by mixing a phosphorus-containing acid with an alkali metal hydroxide salt and an ammonium/amine compound to create an exothermic reaction thereby producing the active phosphorus-solution; and    contacting the non-ferrous metal component with the active phosphorus solution in a contact region on the non-ferrous metal component to form the non-ferrous metal-phosphate conversion surface on the contact region.    
     
     
         30 . The method of  claim 29  wherein the non-ferrous metal component comprises aluminum.  
     
     
         31 . The method of  claim 30  wherein the non-ferrous metal component comprises at least part of an engine.  
     
     
         32 . The method of  claim 29  wherein the active phosphorus solution is delivered into contact with the non-ferrous metal in a lubricating environment using a lubricating fluid.  
     
     
         33 . A phosphate-metal layer for aluminum components, the surface comprising: 
 aluminum phosphate; and    aluminum oxide, the aluminum phosphate and aluminum oxide forming the phosphate-metal layer on an aluminum component, the phosphate-metal layer being formed as a result of contacting the aluminum component with an amount of a phosphorous-containing solution of  claim 1  operable to create the phosphate-metal layer.