GB2173511A - Application of stop-off coating by ion plating - Google Patents
Application of stop-off coating by ion plating Download PDFInfo
- Publication number
- GB2173511A GB2173511A GB08607476A GB8607476A GB2173511A GB 2173511 A GB2173511 A GB 2173511A GB 08607476 A GB08607476 A GB 08607476A GB 8607476 A GB8607476 A GB 8607476A GB 2173511 A GB2173511 A GB 2173511A
- Authority
- GB
- United Kingdom
- Prior art keywords
- stop
- coating
- substrate
- pattern
- areas
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
- C23C14/24—Vacuum evaporation
- C23C14/32—Vacuum evaporation by explosion; by evaporation and subsequent ionisation of the vapours, e.g. ion-plating
Abstract
A method of applying a dense tightly adhering stop-off coating to the surface of a substrate including steps of introducing the substrate into an inert atmosphere maintained at a low pressure and depositing on said surface the said stop-off material by means of an ion-plating process. The substrate being a metal blank part of an article to be produced by a plastic forming and diffusion bonding process or it may be a mould tool for use in a superplastic forming process. The stop-off material is preferably Yttria boron nitride, graphite or Alumina and the coating has a thickness of the order of 2 microns.
Description
SPECIFICATION
Application of stop-off coating
This invention relates to the application of
stop-off coating to the surfaces of metals for use in superplastic forming and/or diffusion
bonding processes.
; Stop-off coating is a coating of material
which prevents bonding of adjacent metal
parts in a superplastic forming and/or diffusion
bonding process. In one type of conventional
process, two sheets of metal material are
bonded at selected areas by diffusion bonding whiist leaving other areas unbonded and then
superplastically deformed to form a desired
structure; stop-off coating is applied to those
areas where bonding is not required. In the
bonding and forming process, the sheets are
initially urged together so that they bond at
areas not treated with stop-off coating and
then an inert fluid under pressure is admitted
between the sheets to cause those areas
treated with stop-off coating to be urged
apart into contact with a mould tool.
In the past, methods of applying stop-off
coating have comprised making up a paint or
spray composition containing stop-off material
such as yttria in particulate form together with
a solvent binder. The composition is then ap
plied to the masked off relevant areas by
painting or spraying. It is found however that
stop-off coating applied in this manner does
not possess good adhesion to the underlying
metal; the coating is relatively thick, and its
method of application is such that it is not
possible to lay down precise patterns of stop
off coating which adhere sufficiently well to
allow proper handling of the material.In the
manufacture of certain structures where it is
wished to produce a line bond in the diffusion
bonding process, it is necessary to provide a
pattern in which a fine line of uncoated ma
terial is present between two areas of coated
material, so that the line bond is formed dur
ing the subsequent bonding process. In the
prior art processes it is not possible to lay
down a relatively thin, dense coating and thus
the definition at the edge of an area of stop
off coating is poor.
According to one aspect of this invention, there is provided a method of applying a stop
off coating to the surface of a substrate, the
method including the steps of introducing the
substrate into an inert atmosphere maintained
at a low pressure and depositing on said sur
face a stop-off material by means of an ion
plating process.
The substrate may be a metal blank forming
a part of an article to be produced by a su
perplastic forming and diffusion bonding pro
cess or it may be a mould tool for use in a
superplastic forming process. The stop-off
material may comprise a conventional material
such as yttria, boron nitride, graphite or alumina, yttria being particularly preferred.
By the above method a tightly adhering dense coating of stop-off coating is obtained, having a thickness typically of the order of 2 microns.
According to another aspect of this invention, there is provided a method of applying a predetermined pattern of stop-off coating to the surface of a substrate, the method including the steps of:
(i) introducing the substrate into an inert
atmosphere maintained at a low pres
sure,
(ii) depositing on said surface a coating of
stop-off material by means of an ion
plating process, and
(iii) selectively removing areas of said stop
off coating by means of a photoresist
process thereby to obtain said predeter
mined pattern.
According to yet a further aspect of this invention, there is provided a method of applying a predetermined pattern of stop-off coating to the surface of a substrate, the method including the steps of:
(i) introducing the substrate into an inert
atmosphere maintained at low pressure,
(ii) depositing on said surface a coating of
stop-off material by means of an ion
plating process,
(iii) depositing on said coating of stop-off
material by a silk screen process a layer
of known acid-resistant material in said
predetermined pattern.
(iv) selectively removing areas of said stop
off coating by means of an acid etching
process thereby to obtain said predeter
mined pattern.
By this method it is possible to deposit intricate patterns of stop-off coating to metal blanks in which the resolution of the edges of areas of stop-off coating are well defined and in which the thickness of the coating is substantially reduced. The reduction of the thickness of the coating is advantageous for coating of blanks of superplastic diffusion bonda ble material for it means that the diffusion bonding process will occur early in the bonding and forming cycle.
For a better understanding of the invention a specific example of a method of application of stop-off coating to a metal blank will now be given.
The metal blank is to be provided with an intricate pattern of yttria prior to a superplastic forming and diffusion bonding process. The metal blank is given an initial chemical preclean to remove dirt and grease, etc. The cleaned blank is introduced into a vapour deposition chamber which contains an inert atmosphere, e.g. argon, and the pressure reduced to a low level, typically 10-4 to 10-2 torr, and maintained there for the duration of the vapour deposition cycle.
The blank is initially subjected to a glow discharge process thus to cause ion cleaning of the surface. Immediately thereafter, yttria is deposited on the surface of the part using an ion plating process, the thickness of the layer of yttria typically being of the order of 2 microns.
The blank with its tightly adhering thin but dense layer of yttria is removed from the vapour deposition chamber. In one arrangement a layer of photoresist is applied in known manner over the yttria coating and then 4- posed to U.V. light via an overlaid negative transparency corresponding to the final pattern of stop-off coating for the blank. The unexposed regions of the photoresist coating are then removed in known manner, leaving photoresist covering only those regions where yttria is required. The blank is then immersed in a bath containing a dilute acid for a period sufficient to dissolve away those exposed areas of yttria. The remaining photoresist is then removed, leaving the blank with a welldefined pattern of tightly adhering thin but dense coating of yttria.
In a further arrangement a layer of known acid resistant material (e.g. 'COATES' soluble etch resist XZ-06) is applied by means of a silk screen process over the yttria coating the screen arranged such that the pattern of acid resistant material is representative of the final pattern of stop-off coating for the blank. The blank is then immersed in a bath containing a dilute acid for a period containing a dilute acid for a period sufficient to dissolve away the exposed areas of stop-off. The layer of acid resistant material is subsequently removed by organic solvent means leaving the blank with a well defined pattern of tightly adhering thin but dense coating of Yttria.
Blanks treated in this way may be assembled together, diffusion bonded and superplastically formed to form composite structures.
The method of application is of particular benefit where it is intended that a thin but continuous diffusion bond is to be made prior to superplastic inflation of adjacent cells.
In addition, the above method of application of yttria may be used to coat the hot-form tools used in superplastic processes, to prevent contamination of the superplastically deformed component and also to act as a release agent between the component and the tool.
At present, these coatings are sprayed or baked onto the tool prior to each forming process. It is envisaged that coating of the tool with stop-off coating using the above method, but without the subsequent photo-etching or acid etching process will considerably extend tool utilisation before surface retreatment is necessary.
Claims (14)
1. A method of applying a stop-off coating to the surface of a substrate, the method including the steps of introducing the substrate into an inert atmosphere maintained at low pressure and depositing on said surface a stop-off material by means of an ion-plating process.
2. A method according to claim 1 wherein the substrate is a metal blank forming part p.f an article to be produced by a superplastict forming and diffusion bonding process. I
3. A method according to claim 1 wherein the substate is a mould tool for use in a superplastic and diffusion bonding process.
4. A method according to claim 1 wherein the stop-off material is a conventional material selected from the group comprising yttria, boron nitrate, graphite and alumina.
5. A method of applying a predetermined pattern of stop-off coating to the surface of a substrate, the method including the steps of:
(i) introducing the substrate into an inert
atmosphere maintained at a low pres
sure
(ii) depositing on said surface a coating of
stop-off material by means of an ion
plating process, and
(iii) selectively removing areas of said stop
off coating by means of a photoresist
process thereby to obtain said predeter
mined pattern.
6. A method of applying a predetermined pattern of stop-off coating to the surface of a substrate, the method including the steps of:
(i) introducing the substrate into an inert
atmosphere maintained at low pressure,
(ii) depositing on said surface a coating of
stop-off material by means of an ion
plating process,
(iii) depositing on said coating of stop-off
material by a silk-screen process a layer
of known acid-resistant material in said
predetermined pattern.
(iv) selectively removing areas of said stop
off coating by means of an acid etching
process thereby to obtain said predeter
mined pattern.
7. A method according to claim 1 or claim 5 or claim 6 in which the inert atmosphere is reduced to a low pressure in the range of 10- 4 to 10 2 torr and maintained thereat for the duration of the vapour deposition cycle.
8. A method according to claim 1 or claim 5 or claim 6 in which the coating of stop-off material is of a thickness of the order of 2 microns.
9. A method according to claim 5 in which a layer of photoresist is applied in known manner over the stop-off coating and then exposed to ultra-violet light via an overlaid negative transparency corresponding to the desired final pattern of stop-off coating for the substrate so that the unexposed regions of the photoresist coating are removed leaving photoresist only in those regions where the stopoff coating is required.
10. A method according to claim 9 in which the substrate is immersed in a bath containing acid for a period sufficient to dissolve away exposed areas of stop-off material then removing the remaining photoresist leaving the substrate with a well defined pattern of a tightly adhering thin but dense coating of stop-off material.
11. A method according to claim 6 in which the substrate is immersed in a bath containing acid for a period sufficient to dissolve away, exposed areas of stop-off material then removing by organic solvent means the layer of acid resistant material leaving the substrate with a well defined pattern of a tightly adhering thin but dense coating of stop-off material.
12. A method of making a composite metal structure wherein a plurality of metal workpieces are subject to heat and pressure to effect diffusion bonding except in predetermined areas wherein an applied stop-off composition prevents bonding taking place and introducing fluid pressure to separate the work pieces in said predetermined areas and effecting superplastic forming in at least one of the workpieces, characterised in that a stop-off composition is applied by a method in accordance with claims 1 or claim 5 or claim 6.
13. A method of applying a stop-off coating to the surface of a substrate substantially as hereinbefore described.
14. A method of making a composite metal structure as hereinbefore described.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB858508338A GB8508338D0 (en) | 1985-03-29 | 1985-03-29 | Application of stop-off coating |
Publications (3)
| Publication Number | Publication Date |
|---|---|
| GB8607476D0 GB8607476D0 (en) | 1986-04-30 |
| GB2173511A true GB2173511A (en) | 1986-10-15 |
| GB2173511B GB2173511B (en) | 1989-09-13 |
Family
ID=10576936
Family Applications (2)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB858508338A Pending GB8508338D0 (en) | 1985-03-29 | 1985-03-29 | Application of stop-off coating |
| GB8607476A Expired GB2173511B (en) | 1985-03-29 | 1986-03-26 | Application of stop-off coating |
Family Applications Before (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB858508338A Pending GB8508338D0 (en) | 1985-03-29 | 1985-03-29 | Application of stop-off coating |
Country Status (1)
| Country | Link |
|---|---|
| GB (2) | GB8508338D0 (en) |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5287918A (en) * | 1990-06-06 | 1994-02-22 | Rolls-Royce Plc | Heat exchangers |
| US5385204A (en) * | 1989-08-25 | 1995-01-31 | Rolls-Royce Plc | Heat exchanger and methods of manufacture thereof |
| US5505256A (en) * | 1991-02-19 | 1996-04-09 | Rolls-Royce Plc | Heat exchangers and methods of manufacture thereof |
| US5513791A (en) * | 1994-03-28 | 1996-05-07 | General Electric Company | Strippable mask patterning of stop-off for diffusion bond processing |
Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB1427674A (en) * | 1973-03-05 | 1976-03-10 | Suwa Seikosha Kk | Process for coating a material onto a timepiece part |
| GB1431935A (en) * | 1972-07-22 | 1976-04-14 | Philips Nv | Chemically resistant material |
| GB1493088A (en) * | 1975-02-12 | 1977-11-23 | Takagi Toshinori | Insulating substrate with metallic coating and method for manufacturing same |
| GB2010919A (en) * | 1977-12-23 | 1979-07-04 | Balzers Hochvakuum | Method for the manufacture of gold-coloured coatings |
| GB2090291A (en) * | 1980-12-22 | 1982-07-07 | Secr Defence | Sputter ion plating of refractory metal/metal compounds |
| GB2106145A (en) * | 1981-09-23 | 1983-04-07 | Energy Conversion Devices Inc | Wear resistant coating |
| GB2158104A (en) * | 1984-05-04 | 1985-11-06 | Diesel Kiki Co | Method for producing a thin film |
-
1985
- 1985-03-29 GB GB858508338A patent/GB8508338D0/en active Pending
-
1986
- 1986-03-26 GB GB8607476A patent/GB2173511B/en not_active Expired
Patent Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB1431935A (en) * | 1972-07-22 | 1976-04-14 | Philips Nv | Chemically resistant material |
| GB1427674A (en) * | 1973-03-05 | 1976-03-10 | Suwa Seikosha Kk | Process for coating a material onto a timepiece part |
| GB1493088A (en) * | 1975-02-12 | 1977-11-23 | Takagi Toshinori | Insulating substrate with metallic coating and method for manufacturing same |
| GB2010919A (en) * | 1977-12-23 | 1979-07-04 | Balzers Hochvakuum | Method for the manufacture of gold-coloured coatings |
| GB2090291A (en) * | 1980-12-22 | 1982-07-07 | Secr Defence | Sputter ion plating of refractory metal/metal compounds |
| GB2106145A (en) * | 1981-09-23 | 1983-04-07 | Energy Conversion Devices Inc | Wear resistant coating |
| GB2158104A (en) * | 1984-05-04 | 1985-11-06 | Diesel Kiki Co | Method for producing a thin film |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5385204A (en) * | 1989-08-25 | 1995-01-31 | Rolls-Royce Plc | Heat exchanger and methods of manufacture thereof |
| US5287918A (en) * | 1990-06-06 | 1994-02-22 | Rolls-Royce Plc | Heat exchangers |
| US5505256A (en) * | 1991-02-19 | 1996-04-09 | Rolls-Royce Plc | Heat exchangers and methods of manufacture thereof |
| US5513791A (en) * | 1994-03-28 | 1996-05-07 | General Electric Company | Strippable mask patterning of stop-off for diffusion bond processing |
Also Published As
| Publication number | Publication date |
|---|---|
| GB8607476D0 (en) | 1986-04-30 |
| GB2173511B (en) | 1989-09-13 |
| GB8508338D0 (en) | 1985-05-09 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| 732E | Amendments to the register in respect of changes of name or changes affecting rights (sect. 32/1977) | ||
| PCNP | Patent ceased through non-payment of renewal fee |
Effective date: 20050326 |