Fiber and sheet equipment wear surfaces of extended resistance and methods for their manufacture
A method for producing process equipment having a wear surface having extended resistance to one or more of abrasion, erosion, or corrosion, associated with materials processed by said process equipment includes applying to said process. equipment wear surface a metal matrix coating filled with superabrasive particles. Diamond and cubic boron nitride superabrasive particles can fill the metal matrix, which can be a nickel coating.
1 - 42 . (canceled)
43 . Process equipment, comprising:
a continuous fiber wear surface having a composite coating, wherein the composite coating comprises a metal and superabrasive particles.
44 . The process equipment of claim 43 , wherein the continuous fiber wear surface comprises a surface that, when used, is subject to abrasion, corrosion or erosion by the processing of a continuous fiber or sheet.
45 . The process equipment of claim 43 , wherein:
the composite coating comprises between about 5 and about 80 volume-percent superabrasive particles;
the average particle size of the superabrasive particles ranges from about 0.1 to about 50 microns;
the metal comprises nickel, nickel alloys, silver, a silver alloy, tungsten, a tungsten alloy, iron, an iron alloy, aluminum, an aluminum alloy, titanium, a titanium alloy, copper, a copper alloy, chromium, a chromium alloy, tin, a tin alloy, cobalt, a cobalt alloy, zinc, a zinc alloy, a transition metal, or a transition metal alloy; and
the coating has a thickness from about 0.5 to about 1000 microns.
46 . The process equipment of claim 43 , wherein the coating further comprises nickel, a nickel alloy, silver, a silver alloy, tungsten, a tungsten alloy, boron, tantalum, stainless steel, chromium, molybdenum, vanadium, zirconium, titanium, tungsten, a ceramic, a glass, talcum, a plastic, a metal graphite, a metal oxide, a metal silicide, a metal carbonate, a metal carbide, a metal sulfide, a metal phosphate, a metal boride, a metal silicate, a metal oxylate, a metal nitride, or a metal fluoride.
47 . The process equipment of claim 46 , wherein the coating further comprises hexagonal boron nitride (hBN), SiC, Si 3 N4, WC, TiC, CrC, B 4 C, or Al 2 O 3 .
48 . The process equipment of claim 43 , wherein the coating is overcoated with an organic coating comprising a phenolic resin, epoxy resin, aminoplast resin, urethane resin, acrylate resin, isocyanurate resin, acrylated isocyanurate resin, urea-formaldehyde resin, acrylated epoxy resin, or acrylated urethane resin.
49 . The process equipment of claim 43 , wherein the wear surface is that of a fiber sizing surface.
50 . The process equipment of claim 43 , wherein the wear surface is a that of a collection comb.
51 . The process equipment of claim 43 , wherein the wear surface is that of a fiber winding spool.
52 . A method of producing process equipment, comprising:
applying to a continuous fiber wear surface a composite coating that comprises a metal and superabrasive particles.
53 . The method of claim 52 , wherein the wear surface is that of a fiber sizing surface.
54 . The method of claim 52 , wherein the wear surface is that of a collection comb.
55 . The method of claim 52 , wherein the wear surface is that of a fiber winding spool.
56 . The method of claim 52 , wherein the applying comprises:
depositing, via an electroplating process, metal onto the wear surface until a desired thickness is achieved; and
introducing superabrasive particles into a plating bath of the electroplating process, wherein the superabrasive particles comprise about 5% to about 30% by volume of the plating bath.
57 . The method of claim 56 , further comprising applying an organic size coating over the composite coating.
58 . The method of claim 52 , wherein the applying comprises:
submerging the wear surface in a stable electroless bath comprising a metal salt, al electroless reducing agent, a complexing agent, an electroless plating stabilizer, and superabrasive particulates; and
maintaining the superabrasive particulates in suspension in the bath for a time sufficient to produce the composite coating at a desired thickness on the wear surface.
59 . The method of claim 58 , further comprising applying an organic coating over the composite coating, wherein the organic coating comprises a phenolic resin, epoxy resin, aminoplast resin, urethane resin, acrylate resin, isocyanurate resin, acrylated isocyanurate resin, urea-formaldehyde resin, acrylated epoxy resin, or acrylated urethane resin.
60 . The method claim 58 , wherein the bath further comprises ceramics, glass, talcum, plastic, graphite, oxides, silicides, carbonates, carbides, sulfides, phosphates, borides, silicates, oxylates, nitrides, fluorides, metal or an alloy.