US 12,240,983 B2
Method of forming protective coating
John R. Nicholls, Crainfield (GB); Victoria Louise Minns, Cranfield (GB); and David S. Rickerby, Derby (GB)
Assigned to Rolls-Royce PLC, London (GB)
Filed by ROLLS-ROYCE plc, London (GB)
Filed on Dec. 6, 2022, as Appl. No. 18/062,041.
Claims priority of application No. 2118927 (GB), filed on Dec. 23, 2021.
Prior Publication US 2023/0203316 A1, Jun. 29, 2023
Int. Cl. C23C 2/12 (2006.01); C09D 1/00 (2006.01); C23C 22/20 (2006.01); C23C 22/78 (2006.01)
CPC C09D 1/00 (2013.01) [C23C 22/20 (2013.01); C23C 22/78 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A method of forming a protective coating, the method comprising:
providing a substrate comprising at least one chemical element and a surface;
forming a basecoat composition comprising an aluminium phase comprising aluminium;
wherein the basecoat layer comprises a binder phase comprising at least one of a phosphate salt and a chromate salt, and wherein the aluminium phase is dispersed in the binder phase;
applying the basecoat composition on the surface of the substrate to form a basecoat layer;
heating the basecoat layer to a first temperature (T1) for a predetermined period of time;
applying a glow discharge plasma on the basecoat layer;
heating the basecoat layer to a second temperature (T2) greater than the first temperature (T1), in order to activate an exothermic reaction between at least the aluminium phase of the basecoat layer and the at least one chemical element of the substrate, wherein the exothermic reaction forms the protective coating on the surface of the substrate; and
eliminating the binder phase from the protective coating.