US 12,291,784 B2
Corrosion protection using metallic coating
Tahany El-Wardany, Vernon, CT (US); Kenneth D. Smith, East Longmeadow, MA (US); Tianli Zhu, Glastonbury, CT (US); Weilong Zhang, Glastonbury, CT (US); and Sergey Mironets, Philadelphia, PA (US)
Assigned to GOODRICH CORPORATION, Charlotte, NC (US)
Filed by Goodrich Corporation, Charlotte, NC (US)
Filed on Oct. 7, 2022, as Appl. No. 17/962,367.
Prior Publication US 2024/0117497 A1, Apr. 11, 2024
Int. Cl. C23C 26/00 (2006.01); B33Y 10/00 (2015.01); B33Y 50/02 (2015.01)
CPC C23C 26/00 (2013.01) [B33Y 10/00 (2014.12); B33Y 50/02 (2014.12)] 12 Claims
OG exemplary drawing
 
1. A method, comprising:
receiving a workpiece of a second material;
contacting the workpiece with a sacrificial deposition rod, the sacrificial deposition rod comprising a first material fabricated using a shear assisted processing and extrusion process, wherein the first material includes an icosahedral phase (I-phase) aluminum alloy;
performing a first deposition process to form a first layer of a coating of the first material on the workpiece, the first deposition process including rotating the sacrificial deposition rod at a first rotation per minute to form the first layer to have a first grain type;
performing a second deposition process to form a second layer of the coating of the first material over the first layer, the second deposition process including rotating the sacrificial deposition rod a second rotation per minute to form the second layer to have a second grain type, wherein the first layer and the second layer have a first thickness; and
machining the coating to a second thickness that is less than the first thickness, wherein the machining comprises at least one of grinding or sanding;
wherein the shear assisted processing and extrusion process includes:
moving a powder comprising an icosahedral phase (I-phase) aluminum alloy into a billet container that is disposed around a mandrel;
heating the powder in the billet container with a heating element;
moving the powder from the billet container through spiral grooves in an extruding tube to form a billet; and
extruding the billet through the extruding tube with the mandrel to form the sacrificial deposition rod.