Aluminum Company of America

Karl Wefers

Larry F Wieserman

Gary A Nitowski

Edward S Martin

Kathryn Cross

Chanakya Misra

Maya Fishkis

Larry T Taylor

Frank A Mozelewski

John W Novak, Jr

H Philip Hsieh

William H Quayle

Christine M Conroy

Richard H Bott

A method for wetting and bonding refractory alumina or aluminosilicate fibers or particles with molten aluminum or aluminum alloys by forming a boron oxidized interface between the fiber and the metal is exists. The method comprises the steps of (a) coating alumina fibers with an effective amount of a thermally decomposable precursor of boron oxide; (b) heating the coated fiber sufficiently to form a boron oxide; and (c) forming a composite with aluminum metal or an aluminum alloy. Thermally decomposable precursors of boron oxide include ammonium pentaborate, ammonium diborate and orthoboric acid.

Fiber reinforced aluminum matrix composite with improved interfacial

A laminate suitable for vehicular applications includes at least two sheets of aluminum alloy and an adhesive layer between the sheets bonding them together. An oxide layer on surfaces of the sheets is treated with a phosphorous acid electrolyte, so that a coordination number of four predominates for the aluminum-oxygen-phosphorous bond. Equivalent bonding strengths in the laminates are obtained in substantially less time with phosphorous acid treatment compared with phosphoric acid treatment.

Adhesively bonded aluminum

An aluminum alloy matrix composite containing alumina or aluminum silicate reinforcement whereby said composite material exhibits wetting between said reinforcement and said aluminum alloy. The composite comprises (a) alumina or aluminosilicate reinforcement; (b) a matrix of aluminum or aluminum alloy; and (c) an intelayer of mixed oxides of aluminum and boron wherein the interlayer of mixed oxides of aluminum and boron includes but is not limited to the following oxides, B.sub.2 O.sub.3, Al.sub.2 O.sub.3, 2Al.sub.2 O.sub.3.B.sub.2 O.sub.3 and 9Al.sub.2 O.sub.3 2B.sub.2 O.sub.3 at the interface between said reinforcement and said matrix.

Method for increasing the wettability of aluminum metal to alumina

A twice-anodized aluminum substrate is anodized sequentially in first and second aqueous electrolytes. In the first, the substrate is conventionally anodized to produce (i) a porous anodic oxide layer having open pores and a passivation layer thereunder. The substrate, now singly-coated, is then anodized in the second electrolyte of an aqueous solution of an organophosphorus compound which generates a residue which is chemisorbed and covalently bonded to the substrate to form (ii) a monomolecular essentially continuous monolayer on the outer surface of (i), and at the same time, the second anodizing step produces (iii) a barrier layer of non-porous aluminum oxide under (i). The thickness of this barrier layer can be increased as a function of the voltage used while maintaining the thickness of (i) substantially constant, and (ii) protects (i) from dissolution. Depending upon the choice of the organophosphorus compound, a hydrophobic, or chemically resistant surface may be produced; or, a surface which provides a leaving group to be reacted with an appropriate organic coating to be applied after the triplex layer is formed.

Twice-anodized aluminum article having an organo-phosphorus monolayer

Disclosed is a food or beverage container or container panel comprised of an aluminum alloy body having an integral bottom and wall. An intermediate layer comprised of an aluminum oxide or aluminum hydroxide layer is bonded to the aluminum alloy body and a functionalized layer of an organo phosphonate, organo phosphinate or phosphate ester is bonded to the oxide or hydroxide layer. A polymer layer is bonded to the functionalized layer. The functionalized layer is comprised of the reaction product of phosphonic or phosphinic acid and/or phosphonic acid ester, for example.

Food or beverage container or container panel

Disclosed is a method of producing a functionalized layer and an aluminum hydroxide layer on an aluminum substrate, the aluminum hydroxide layer located between the substrate and the functionalized layer. The method comprises the steps of subjecting an aluminum substrate to a hydrothermal treatment in an aqueous solution having a pH in the range of 2 to 14 to form a layer of aluminum hydroxide on said substrate and thereafter treating said aluminum substrate with a phosphorus-containing acid selected from phosphinic and phosphonic acid to form a functionalized layer on said aluminum hydroxide layer, the functionalized layer comprised of the reaction product of said acid and the layer of aluminum hydroxide.

Phosphonic/phosphinic acid bonded to aluminum hydroxide layer

Disclosed is a process for anodically oxidizing aluminum alloy surfaces as a pretreatment for structural adhesive bonds or laminates. The process is comprised of anodically oxidizing aluminum and its alloys in phosphorous acid containing electrolyte to form a porous film comprised of Al, O and P. This film provides a very effective substrate for adhesively bonding aluminum articles and laminates.

Process for making an adhesively bonded aluminum article

A process is disclosed for treating the surface of a valve metal such as aluminum to form a two layer protective coating thereon using an anodizing bath consisting essentially of an aqueous solution having a concentration ranging from about 0.001 molar to a saturated solution of a monomeric phosphorus- containing compound selected from the class consisting of a 1-30 carbon water soluble phosphonic acid, a 1-30 carbon water soluble phosphinic acid, and mixtures thereof. The valve metal surface is anodized in the anodizing bath while maintaining a voltage selected from a range of from about 1 to about 400 volts until the current density falls to a level indicative of the fact that a nonporous valve oxide layer has been formed on the valve metal surface and a reaction product from the monomeric phosphonic/phosphinic acid compound is chemically bonded to the oxide layer.

Anodic phosphonic/phosphinic acid duplex coating on valve metal surface

A treated permeable inorganic membrane is disclosed comprising a permeable inorganic membrane capable of reacting with an organic acid. The treated membrane has good chemical stability over a pH range of from 1 to 14, is capable of controlling the flux through the membrane, has altered internal and external wetting properties of the membrane surface, and has controlled pore size due to the presence of a monomolecular layer of an organic acid material chemically bonded to the surface of the inorganic membrane. The monomolecular layer of organic acid material is formed on the membrane surface by contacting the membrane with an organic acid reactant selected from the class consisting of phosphonic acid having the formula RPO(OH).sub.2 ; phosphinic acid having the formula RR'PO(OH); monocarboxylic acids having the formula RCOOH; dicarboxylic acids having the formula R'(COOH).sub.2 ; boronic acid having the formula RB(OH).sub.2 ; and one or more precursors of the foregoing acids which decompose to form the acid functionality; where R comprises a 1-30 carbon-containing group, R' comprises hydrogen or a 1-30 carbon-containing group, and R' comprises a 2-30 carbon-containing group. Excess organic acid reactant not bonded to the underlying membrane surface is removed to ensure formation of said monomolecular layer of said organic acid material on the surfaces of said permeable inorganic membrane.

Surface treated permeable inorganic membranes and process of making same

Method of making a food or beverage container

A process is disclosed for treating the surface of a valve metal such as aluminum to form a two layer protective coating thereon using an anodizing bath consisting essentially of an aqueous solution having a concentration ranging from about 0.001 molar to a saturated solution of a phosphorus-containing compound selected from the class consisting of a phosphorus acid ester and salts thereof. A non-porous barrier valve metal oxide layer is formed on a surface of the valve metal, and a functionalized layer comprised of a phosphate ester is formed on the oxide layer. The functionalized layer protects the oxide layer against chemical attack by the electrolyte during anodizing

Method of making an anodic phosphate ester duplex coating on a valve

Disclosed is a method of producing a functionalized layer and an aluminum hydroxide layer on an aluminum substrate, the aluminum hydroxide layer located between the substrate and the functionalized layer. The method comprises the steps of subjecting an aluminum substrate to a hydrothermal treatment in an aqueous solution having a pH in the range of 2 to 14 to form a layer of aluminum hydroxide on said substrate and thereafter treating said aluminum substrate with a phosphorus-containing acid selected from phosphonic and phosphonic acid to form a functionalized layer on said aluminum hydroxide layer, the functionalized layer comprised of the reaction product of said acid and the layer of aluminum hydroxide.

A chromatographic packing material is disclosed which comprises generally spherical metal oxide/hydroxide support particles comprising crystals extending radially outward from a central core region and having a shape selected from principally acicular to principally lamellar and having bonded to the surface of said metal oxide/hydroxide support particles a layer of one or more phosphorus-containing organic materials comprised of a phosphorus-containing acid group bonded to said metal oxide/hydroxide particles and an unreacted carbon-containing acid group.

Chromatographic packing material comprising extended area metal

A process is disclosed for treating the surface of a valve metal such as aluminum to form a two layer protective coating thereon using an anodizing bath consisting essentially of an aqueous solution having a concentration ranging from about 0.001 molar to a saturated solution of a monomeric phosphorus-containing compound selected from the class consisting of a 1-30 carbon water soluble phosphonic acid, a 1-30 carbon water soluble phosphinic acid, and mixtures thereof. The valve metal surface is anodized in the anodizing bath while maintaining a voltage selected from a range of from about 1 to about 400 volts until the current density falls to a level indicative of the fact that a nonporous valve oxide layer has been formed on the valve metal surface and a reaction product from the monomeric phosphonic/phosphinic acid compound is chemically bonded to the oxide layer.

An active material is disclosed which comprises a metal oxide/hydroxide surface having chemically bonded to reactive sites thereon a substantially monomolecular layer of organic acid molecules. Each organic acid molecule is chemically bonded to a reactive site on the oxide/hydroxide surface through a phosphorus-containing acid group selected from the group consisting of a phosphonic acid group and a phosphinic acid group. Each organic acid molecule also comprises an unreacted acid group oriented away from the metal oxide/hydroxide surface and selected from the class consisting of a phosphonic acid group, a phosphinic acid group, a sulfonic acid group, and a carboxylic acid group.

Growing community of inventors

Apollo, PA, United States of America

Karl Wefers