Coatings containing carbon composite fillers and methods of manufacture

1. An article comprising

a substrate,

a coating disposed on a surface of the substrate, the coating comprising a carbon composite dispersed in one or more of the following: a polymer matrix; a metallic matrix; or a ceramic matrix,

wherein the article is a coated bearing, a coated pipeline, a coated valve, a coated piston, or a coated shaft,

the carbon composite comprises carbon and a binder containing one or more of the following: SiO 2 ; Si; B; B 2 O 3 ; a filler metal; or an alloy of the filler metal,

the filler metal comprises one or more of the following: aluminum; copper; titanium; nickel; tungsten; chromium; iron; manganese; zirconium; hafnium; vanadium; niobium; molybdenum; tin; bismuth; antimony; lead; cadmium; or selenium,

the carbon composite is present in an amount of about 0.1 wt. % to about 75 wt. % based on the total weight of the coating,

the metallic matrix comprises one or more of the following: Ni; Cu; Ag; Au; Sn; Zn; Fe; In; W; Ti; Co; Al; Mg; Cr; or Mo; or an alloy thereof,

the ceramic matrix comprises one or more of the following: an oxide-based ceramic; nitride-based ceramic; carbide-based ceramic; boride-based ceramic; or silicide-based ceramic, the oxide based ceramic being silica or titanium dioxide, and

the polymer matrix comprises a polyaryletherketone, a fluoropolymer, a polyarylene sulfide; a polyarylene, a polyarylene sulfone; a polyether sulfone, a polyarylene ether; a polyurea, a polyurethane; a polycarbonate; a polyimide, a polyetherimide; an ethylene-propylene-diene monomer rubber; a butadiene rubber; a styrene-butadiene rubber; a natural rubber; an acrylonitrile butadiene rubber; a styrene-butadiene-acrylonitrile resin; a butadiene-nitrile rubber; a polyisoprene rubber; an acrylate-butadiene rubber; a polychloroprene rubber; an acrylate-isoprene rubber; an ethylene-vinyl acetate rubber; a polypropylene oxide rubber; or a combination comprising at least one of the foregoing.

2. The article of claim 1 , wherein the carbon composite is present in an amount of about 0.1 wt. % to about 50 wt. % based on the total weight of the coating.

3. The article of claim 1 , wherein the coating has a thickness of about 5 μm to about 10 mm.

4. The article of claim 1 , wherein the carbon composite comprises at least two carbon microstructures; and a binding phase disposed between the at least two carbon microstructures.

5. The article of claim 4 , wherein the binding phase comprises a binder layer and an interface layer bonding one of the at least two carbon microstructures to the binder layer, wherein the interface layer comprises one or more of the following: a C-metal bond; a C—B bond; a C—Si bond; a C—O—Si bond; a C—O-metal bond; or a metal carbon solution.

6. The article of claim 1 , wherein the carbon comprises graphite.

7. The article of claim 1 , further comprising a binding layer disposed between the coating and the substrate.

8. The article of claim 1 , wherein the substrate comprises one or more of the following: a metal; a polymer; or ceramics.

9. A method of making an article of claim 1 , the method comprising:

depositing a matrix material and a carbon composite on a surface of a substrate,

the carbon composite comprising carbon and a binder;

the binder comprising one or more of the following: SiO 2 ; Si; B; B 2 O 3 ; a metal; or an alloy of the metal; and

the metal comprising one or more of the following: aluminum; copper; titanium; nickel; tungsten; chromium; iron; manganese; zirconium; hafnium; vanadium; niobium; molybdenum; tin; bismuth; antimony; lead; cadmium; or selenium.

10. The method of claim 9 , further comprising combining a matrix material with a carbon composite to form a coating composition.

11. The method of claim 10 , wherein depositing a matrix material and a carbon composite comprises disposing the coating composition on a surface of the substrate.

12. The method of claim 11 , wherein the matrix material comprises a material or a precursor for the polymer matrix, and combining the matrix material with the carbon composite comprises dispersing the carbon composite in a dispersion of the matrix material.

13. The method of claim 12 , wherein disposing the coating composition comprises one or more of the following: spray coating; brushing; screen casting; blade casting; drop casting; spin coating; or molding.

14. The method of claim 11 , wherein the matrix material comprises a material or a precursor for the metallic or ceramic matrix, and the matrix material is combined with a carbon composite and an organic compound to form a coating composition in the form of a paste.

15. The method of claim 4 , wherein disposing the coating composition comprises brushing, immersion dipping, or molding.

16. The method of claim 9 , wherein disposing the matrix material and the carbon composite is an all-solid state coating process.

17. The method of claim 10 , wherein disposing the matrix material and the carbon composite comprises thermal spraying the matrix material and the carbon composite simultaneously on the surface of the substrate.

18. A method of coating a substrate, the method comprising:

depositing a matrix material and a carbon composite on a surface of a substrate to form a coating,

the carbon composite comprising carbon and a binder;

the binder comprising one or more of the following: SiO 2 ; Si; B; B 2 O 3 ; a metal; or an alloy of the metal; and

the metal comprising one or more of the following: aluminum; copper; titanium; nickel; tungsten; chromium; iron; manganese; zirconium; hafnium; vanadium; niobium; molybdenum; tin; bismuth; antimony; lead; cadmium; or selenium,

wherein the coating comprises a metallic matrix, and depositing the matrix material and the carbon composite is conducted via electroplating.