Composite layer and method of forming same
A layer ( 20 ) on a composite ( 22 ) of aluminum ( 26 ) and a non-conductive material ( 24 ) and a method of forming the layer ( 20 ) are described. A first embodiment comprises a method of forming a composite layer ( 101 ) comprising combining a non-conductive material ( 24 ) and aluminum ( 26 ) to form a composite ( 22 ), and electrochemically oxidizing ( 103 ) the aluminum ( 26 ) on a surface of the composite ( 22 ) to form aluminum oxide ( 28 ). In a particular embodiment, the non-conductive material ( 24 ) is diamond. In other particular embodiments, the step of combining ( 101 ) the non-conductive material ( 24 ) and aluminum ( 26 ) comprises at least one of cold spraying and electrolytic codeposition. In another particular embodiment, the oxidizing step ( 103 ) comprises anodizing. In yet another particular embodiment, the oxidizing step ( 103 ) comprises hard anodizing. In yet another embodiment, the invention comprises a composite ( 22 ) of a non-conductive material ( 24 ) and aluminum ( 26 ), the composite ( 22 ) having a layer ( 20 ) of the non-conductive material ( 24 ) and aluminum oxide ( 28 ), the layer ( 20 ) being formed by the method of the first embodiment. In yet another embodiment, the composite ( 22 ) is attached to a lapping plate ( 30 ).
1 . A method of forming a layer on a composite, the composite comprising a non-conductive material and aluminum, the method comprising the steps of:
combining a non-conductive material and aluminum to form a composite and
electrochemically oxidizing said aluminum on a surface of said composite to form aluminum oxide.
2 . The method of claim 1 wherein said non-conductive material comprises diamond.
3 . The method of claim 2 wherein said combining step comprises at least one of cold spraying and electrolytic codeposition.
4 . The method of claim 2 wherein said oxidizing step comprises anodizing.
5 . The method of claim 4 wherein said oxidizing step comprises hard anodizing.
6 . The method of claim 1 wherein said combining step comprises at least one of cold spraying and electrolytic codeposition.
7 . The method of claim 6 wherein said oxidizing step comprises anodizing.
8 . The method of claim 7 wherein said oxidizing step comprises hard anodizing.
9 . The method of claim 1 wherein said oxidizing step comprises anodizing.
10 . The method of claim 9 wherein said non-conductive material comprises diamond and said combining step comprises at least one of cold spraying and electrolytic codeposition.
11 . The method of claim 9 wherein said oxidizing step comprises hard anodizing.
12 . The method of claim 11 wherein said non-conductive material comprises diamond and said combining step comprises at least one of cold spraying and electrolytic codeposition.
13 . A composite having a layer comprising particles of a non-conductive material incorporated into crystalline aluminum oxide, the composite comprising a non-conductive material and aluminum, wherein said layer is formed by the steps of:
combining a non-conductive material and aluminum to form a composite; and
electrochemically oxidizing said aluminum on a surface of said composite to form aluminum oxide.
14 . The composite of claim 13 wherein said non-conductive material comprises diamond.
15 . The composite of claim 14 wherein said combining step comprises at least one of cold spraying and electrolytic codeposition.
16 . The composite of claim 14 wherein said oxidizing step comprises anodizing.
17 . The composite of claim 16 wherein said oxidizing step comprises hard anodizing.
18 . The composite of claim 13 wherein said combining step comprises at least one of cold spraying and electrolytic codeposition.
19 . The composite of claim 18 wherein said oxidizing step comprises anodizing.
20 . The composite of claim 19 wherein said oxidizing step comprises hard anodizing.
21 . The composite of claim 13 wherein said oxidizing step comprises anodizing.
22 . The composite of claim 21 wherein said non-conductive material comprises diamond and said combining step comprises at least one of cold spraying and electrolytic codeposition.
23 . The composite of claim 21 wherein said oxidizing step comprises hard anodizing.
24 . The composite of claim 23 wherein said non-conductive material comprises diamond and said combining step comprises at least one of cold spraying and electrolytic codeposition.
25 . The composite of claim 13 wherein said layer is formed on a first side of said composite and said composite further comprises a lapping plate attached to a second side of said composite.