Functionally Graded Coatings and Claddings for Corrosion and High Temperature Protection

1 . A method for producing a functionally-graded coating, comprising:

(a) exposing a mandrel or a substrate to be coated to an electrolyte containing one or more metal ions, and containing one or more ceramic particles, polymer particles, pre-ceramic polymer particles, active fillers, or a combination thereof;

(b) applying an electric current and changing in time one or more of: an amplitude of the electrical current, an amplitude of an electrical potential, an electrolyte temperature, a relative concentration of metal ions or particles in the electrolyte, or an electrolyte agitation, to change a ratio of an electrodeposited species; and

(c) promoting growth of the functionally-graded coating until a desired thickness of the coating is achieved, the electrodeposited species being varied throughout the desired thickness of the coating.

2 . (canceled)

3 . The method of claim 1 , further comprising heat treating the coating to cause partial or complete sintering of a pre-ceramic polymer applied to said mandrel or substrate by said applying of said electric current.

4 . The method of claim 3 , where the heat treating has a heat treatment temperature between 200 degrees C. to 1300 degrees C.

5 - 6 . (canceled)

7 . The method of claim 1 , wherein said one or more metal ions are selected from the group consisting of: Ni, Zn, Fe, Cu, Au, Ag, Pd, Sn, Mn, Co, Pb, Al, Ti, Mg, and Cr.

8 . The method of claim 1 , wherein the ceramic particles are chosen from metal oxides, carbides, nitrides, or combinations thereof.

9 - 12 . (canceled)

13 . The method of claim 1 ,

wherein the polymer particles comprise one or more of: epoxy, polyurethane, polyaniline, polyethylene, poly ether ether ketone, polypropylene, and siloxane;

wherein the pre-ceramic polymer particles comprise one or more of: siloxides, silences, silanes, organosilanes, siloxanes, polyhedral oligomeric silsesquioxanes, polydimethylsiloxanes, and polydiphenylsiloxanes; and/or

wherein the active fillers comprise one or more of: titanium disilicide, yittrium disilicide, nickel disilicide, niobium disilicide, tantalum disilicide, vanadium disilicide, chromium disilicide, and molybdenum disilicide.

14 .- 24 . (canceled)

25 . A coating prepared by the method of claim 1 .

26 . An electrodeposited corrosion-resistant functionally-graded coating, comprising:

an interior first region of metal; and

an exterior second region of polymer, pre-ceramic polymer, or ceramic,

wherein a non-discrete region is disposed between the first region and the second region, the non-discrete region being a combination of the first region and the second region.

27 . The functionally-graded coating of claim 26 , wherein said non-discrete region has a monotonically increasing metal concentration gradient.

28 . The functionally-graded coating of claim 26 , wherein said non-discrete region has a monotonically decreasing metal concentration gradient.

29 . The functionally-graded coating of claim 26 , wherein said functionally-graded coating is corrosion-resistant or substantially corrosion resistant, is heat resistant or substantially heat resistant, and/or wear resistant or substantially wear resistant.

30 - 31 . (canceled)

32 . The functionally-graded coating of claim 26 , wherein said metal comprises one or more metal ions selected from the group consisting of:

Ni, Zn, Fe, Cu, Au, Ag, Pd, Sn, Mn, Co, Pb, Al, Ti, Mg, and Cr.

33 . The functionally-graded coating of 26 , wherein said ceramic comprises one or more metal oxides, carbides, nitrides, or combinations thereof.

34 - 37 . (canceled)

38 . The functionally-graded coating of claim 26 , wherein the polymer comprises one or more of: epoxy, polyurethane, polyaniline, polyethylene, poly ether ether ketone, polypropylene, and siloxane; and

wherein the pre-ceramic polymer comprises one or more of: siloxides, silences, silanes, organosilanes, siloxanes, polyhedral oligomeric silsesquioxanes, polydimethylsiloxanes, and polydiphenylsiloxanes.

39 . (canceled)

40 . The functionally-graded coating of claim 26 , further comprising a first substrate disposed proximate to a second substrate comprising iron, copper, zinc, aluminum, titanium, nickel, chromium, graphite, carbon, cobalt, lead, epoxy, or composites or alloys thereof.