Anti-corrosion and anti-erosion protective layer containing aluminium

Abstract

The corrosion and also the erosion properties of a layer system can be improved by using deposition-hardened particles.

1 . A layer system which comprises at least:
 a substrate;   a lower layer of a matrix material on the substrate;   optionally an outer layer of a matrix material on the lower layer;   wherein particles composed of aluminum (Al) having a soft hardness, are present in the matrix material of at least one of the layers of the layer system;   at least one of the layers includes in the matrix material thereof aluminum-containing particles (AL*) which are harder than the soft hardness particles composed of aluminum (Al) wherein the aluminum-containing particles (AL*) comprise an aluminum alloy or a precipitation-hardening aluminum alloy having a hardening mechanism, and the precipitation-hardening aluminum-containing particles (AL*) comprise an alloy of aluminum-zinc (Al—Zn);   
       aluminum-zinc-manganese (Al—Zn—Mn); 
       aluminum-manganese-scandium (Al—Mn—Sc); 
       aluminum-magnesium-manganese (Al—Mg—Mn); 
       aluminum-magnesium-zinc-copper (Al—Mg—Zn—Cu); 
       aluminum-magnesium-zinc-copper-cobalt (Al—Mg—Zn—Cu—Co); and 
       aluminum-copper-manganese-zinc (Al—Cu—Mn—Zn) 
     
     
         2 . (canceled) 
     
     
         3 . The layer system as claimed in  claim 1 , wherein the aluminum-containing particles (AL*) comprise scandium-containing (Sc) aluminum Al alloys:
 Al—Sc, Al—Cu—Sc, Al—Si—Sc, Al—Mg—Si—Sc, Al—Zn—Mg—Sc, Al—Li—Sc and/or Al—Mg—Sc.   
     
     
         4 . The layer system as claimed in  claim 1 , wherein dispersion-hardening aluminum alloys are used for the aluminum-containing particles (AL*), wherein the aluminum-containing particles (AL*) are produced by mechanical alloying. 
     
     
         5 . The layer system as claimed in  claim 1 , wherein the aluminum-containing particles (AL*) are selected from aluminides NiAl, Ni 3 Al, FeAl, Fe 3 Al, TiAl, Ti 3 Al, AlFe 8 , AlFe 8 Co, AlFe 8 Ce 4  and/or AlFe 8 Zr 1 . 
     
     
         6 . The layer system as claimed in  claim 1 , wherein the aluminum-containing particles (AL*) comprise aluminum composites selected from:
 aluminum (Al), an aluminum alloy, selected from alloys Al—Si, Al—Si—Mg, Al—Mn, Al—Fe, Al—Mn—Fe, Al—Ni, Al—Zn, and having an incorporated harder ceramic component which includes oxides or nitrides.   
     
     
         7 . The layer system as claimed in  claim 1 , having a lower layer and no outer layer outward of the lower layer; and
 the lower layer having particles of aluminum selected from aluminum alloy and having hard particles not of aluminum.   
     
     
         8 . The layer system as claimed in  claim 1 , which comprises at least:
 only one lower layer; and   only one outer layer.   
     
     
         9 . (canceled) 
     
     
         10 . the layer system as claimed in  claim 1 , further comprising hard material particles (H) or (AL*) present in the lower layer. 
     
     
         11 . The layer system as claimed in  claim 1 , further comprising hard material particles (H) present in the upper layer along with the aluminum particles. 
     
     
         12 . The layer system as claimed in  claim 1 , further comprising hard material particles (H) present in both layers. 
     
     
         13 . The layer system as claimed in  claim 1 , further comprising hard material particles in at least one of the layers and comprising at least one of aluminum nitride, boron nitride, chromium carbide, aluminum oxide or mixtures thereof 
     
     
         14 . The layer system as claimed in  claim 1 , wherein each of the layers or both of the layers are comprised of the same matrix material, in which the particles are included. 
     
     
         15 . (canceled) 
     
     
         16 . The layer system as claimed in  claim 1 , wherein the substrate is comprised of a steel. 
     
     
         17 . The layer system as claimed in  claim 1 , wherein the aluminum particles have an increased hardness as a result of production thereof including conductivity blasting. 
     
     
         18 . The layer system as claimed in  claim 7 , wherein the lower layer comprises aluminum particles (Al) having a maximum hardness of Hv50, and the upper layer comprises aluminum particles having an at least 10% greater hardness (AL*), wherein precipitation-hardening aluminum alloy particles (AL*) are in the upper layer. 
     
     
         19 . The layer system as claimed in  claim 1 , wherein the upper layer does not comprise any aluminum-containing particles (AL*) or aluminum particles (Al). 
     
     
         20 . The layer system as claimed in  claim 1 , wherein the lower layer is directly on the substrate. 
     
     
         21 . The layer system as claimed in  claim 1 , wherein the soft hardness of the aluminum particles soft hardness is up to Hv50. 
     
     
         22 . The layer system as claimed in  claim 1 , wherein the alloy includes:
 Al 3 Li and/or   AlZn4.5Mg1 and/or   AlZnMgCu1.5 and/or   AlZnMgCu0.5 and/or   AlMg4.5Mn.   
     
     
         23 . The layer system as claimed in  claim 5 , wherein the harder ceramic component includes Al 2 O 3 , Al 4 C 3  and/or SiC 
     
     
         24 . The layer system as claimed in  claim 17 , wherein the conductivity blasting comprises cold strengthening processes, particle blasting or rolling. 
     
     
         25 . A layer system comprising:
 a substrate;   a lower covering layer on the substrate made of a first matrix material;   an outer layer on the lower layer and made of a second matrix material;   the outer layer includes in the second matrix material of the outer layer at least one of aluminum particles and hard aluminum particles and the outer layer optionally includes hard particles not of aluminum.   
     
     
         26 . The layer system as claimed in  claim 2 , wherein the lower layer includes at least one of particles of aluminum, hard aluminum and hard particles not of aluminum.