Preparation of a molybdenum-silicon- phosphorus-transitional metal composite coating bath and process for zinc-nickel plating

Abstract

A method of disposing a corrosion resistant system to a substrate is disclosed. The method includes applying a plating material to the substrate, forming a chemical conversion coating solution by combining a solvent, at least one corrosion inhibitive cation comprising at least one of zirconium, titanium, cerium, vanadium species, manganese, or niobium, and at least one corrosion inhibitive anion comprising at least one of phosphate, molybdate, or silicate, and applying the chemical conversion coating solution to the plating material on the substrate.

What is claimed is: 
     
         1 . A method of disposing a corrosion resistant system to a substrate, comprising:
 applying a plating material to the substrate;   forming a chemical conversion coating solution by combining a solvent, at least one corrosion inhibitive cation comprising at least one of zirconium, titanium, cerium, vanadium species, manganese, or niobium, and at least one corrosion inhibitive anion comprising at least one of phosphate, molybdate, or silicate; and   applying the chemical conversion coating solution to the plating material on the substrate.   
     
     
         2 . The method of  claim 1 , further comprising:
 prior to applying the chemical conversion coating solution to the plating material on the substrate, activating the plating material with an activator, wherein the activator is at least one of nitric acid or alkaline immersion cleaner.   
     
     
         3 . The method of  claim 2 , further comprising:
 prior to activating the plating material with an activator, degreasing the plating material on the substrate, wherein the plating material on the substrate is degreased with at least one of acetone or methyl acetate.   
     
     
         4 . The method of  claim 1 , wherein the chemical conversion coating solution is applied to the plating material on the substrate by dipping the substrate plated with the plating material into a bath of the chemical conversion coating solution for between 2 minutes to 20 minutes, wherein the chemical conversion coating solution comprises at least one complexing agent, at least one oxidizer, and at least one organic polymer additive, wherein the at least one complexing agent is at least one of sulfuric acid, nitric acid, a fluorosilicic acid solution, Ethylenediaminetetraacetic acid (EDTA), tartaric acid, oxalic acid, phytic acid, citric acid, or glycine, wherein the at least one oxidizer is at least one of hydrogen peroxide (H 2 O 2 ) or a permanganate compound, and wherein the at least one polymer additive is at least one of tannic acid, polyacrylic acid, polyvinyl alcohol, or polyvinylpyrrolidone. 
     
     
         5 . The method of  claim 1 , further comprising:
 drying the substrate plated with the plating material and coated with a chemical conversion coating for at least two hours at between 30° C. (86° F.) and 200° C. (392° F.).   
     
     
         6 . The method of  claim 1 , wherein the chemical conversion coating solution has a pH of between 3.5 and 12. 
     
     
         7 . The method of  claim 1 , further comprising:
 forming a corrosion inhibition composition solution by combining at least one of phosphate, molybdate, or silicate; and   applying the corrosion inhibition composition solution to the substrate plated with the plating material and coated with a chemical conversion coating.   
     
     
         8 . The method of  claim 7 , wherein the corrosion inhibition composition solution is applied to the substrate plated with the plating material and coated with the chemical conversion coating on by dipping the substrate plated with the plating material and coated with the chemical conversion coating into a bath of the corrosion inhibition composition solution for between 3 minutes to 12 minutes. 
     
     
         9 . The method of  claim 7 , further comprising:
 drying the substrate plated with the plating material, coated with the chemical conversion coating, and coated with a corrosion inhibition composition coating for at least two hours at between 30° C. (86° F.) and 200° C. (392° F.).   
     
     
         10 . A corrosion inhibition system disposed on a substrate, comprising:
 the substrate;   a plating material disposed on the substrate; and   a chemical conversion coating disposed on the plating material and comprising a corrosion inhibitive cation comprising at least one of zirconium, titanium, cerium, vanadium species, manganese, or niobium, and a corrosion inhibitive anion comprising at least one of phosphate, molybdate, or silicate.   
     
     
         11 . The corrosion inhibition system of  claim 10 , comprising:
 an activator applied to the plating material prior to disposing the chemical conversion coating disposed on the plating material, the activator being at least one of nitric acid or alkaline immersion cleaner.   
     
     
         12 . The corrosion inhibition system of  claim 11 , wherein the plating material is degreased prior to disposing the activator on the plating material and wherein the plating material on the substrate is degreased with at least one of acetone or methyl acetate. 
     
     
         13 . The corrosion inhibition system of  claim 10 , wherein the chemical conversion coating is applied to the plating material on the substrate by dipping the substrate plated with the plating material into a bath of a chemical conversion coating solution for between 2 minutes to 20 minutes, wherein the chemical conversion coating solution comprises at least one complexing agent, at least one oxidizer, and at least one organic polymer additive, wherein the at least one complexing agent is at least one of sulfuric acid, nitric acid, a fluorosilicic acid solution, Ethylenediaminetetraacetic acid (EDTA), tartaric acid, oxalic acid, phytic acid, citric acid, or glycine, wherein the at least one oxidizer is at least one of hydrogen peroxide (H 2 O 2 ) or a permanganate compound, and wherein the at least one polymer additive is at least one of tannic acid, polyacrylic acid, polyvinyl alcohol, or polyvinylpyrrolidone. 
     
     
         14 . The corrosion inhibition system of  claim 10 , wherein the substrate is plated with the plating material and coated with the chemical conversion coating is dried for at least two hours at between 30° C. (86° F.) and 200° C. (392° F.). 
     
     
         15 . The corrosion inhibition system of  claim 10 , wherein the chemical conversion coating has a pH of between 3.5 and 12. 
     
     
         16 . The corrosion inhibition system of  claim 10 , further comprising:
 a corrosion inhibition composition coating disposed on the chemical conversion coating and comprising at least one of phosphate, molybdate, or silicate.   
     
     
         17 . The corrosion inhibition system of  claim 16 , wherein the corrosion inhibition composition coating is applied to the substrate plated with the plating material and coated with the chemical conversion coating on by dipping the substrate plated with the plating material and coated with the chemical conversion coating into a bath of a corrosion inhibition composition solution for between 3 minutes to 12 minutes. 
     
     
         18 . The corrosion inhibition system of  claim 16 , wherein the substrate plated with the plating material, coated with the chemical conversion coating, and coated with the corrosion inhibition composition coating is dried for at least two hours at between 30° C. (86° F.) and 200° C. (392° F.). 
     
     
         19 . A chemical conversion coating solution, comprising:
 a solvent;   at least one corrosion inhibitive cation comprising at least one of zirconium, titanium, cerium, vanadium species, manganese, or niobium;   at least one corrosion inhibitive anion comprising at least one of phosphate, molybdate, or silicate;   at least one complexing agent;   at least one oxidizer; and   at least one organic polymer additive,
 wherein the at least one complexing agent is at least one of sulfuric acid, nitric acid, a fluorosilicic acid solution, Ethylenediaminetetraacetic acid (EDTA), tartaric acid, oxalic acid, phytic acid, citric acid, or glycine, 
 wherein the at least one oxidizer is at least one of hydrogen peroxide (H 2 O 2 ) or a permanganate compound, and 
 wherein the at least one polymer additive is at least one of tannic acid, polyacrylic acid, polyvinyl alcohol, or polyvinylpyrrolidone. 
   
     
     
         20 . The chemical conversion coating solution of  claim 19 , wherein the chemical conversion coating solution has a pH of between 3.5 and 12.