Abstract: An article is coated with a multi-layer decorative and protective coating having the appearance of stainless steel. The coating comprises one or more electroplated layers on the surface of said article and vapor deposited on the electroplated layers a color layer comprised of the reaction products of refractory metal or refractory metal alloy, nitrogen and oxygen wherein the total nitrogen and oxygen content is from about 4 to about 32 atomic percent with the nitrogen content being at least about 3 atomic percent.

Abstract: An article is coated with a multi-layer coating comprising a polymeric layer; a chromium compound, preferably chromium nitride layer; a sandwich layer comprised of a plurality of alternating layers comprised of refractory metal compound or refractory metal alloy compound alternating with layers comprised of refractory metal or refractory metal alloy; a color layer comprised of chromium, metal compound or metal alloy compound; and (i) a metal oxide or metal alloy oxide layer or (ii) a layer comprised of the reaction products of metal or metal alloy, oxygen and nitrogen. The coating provides abrasion protection, corrosion protection, and improved chemical resistance.

Abstract: An article having on at least a portion of its surface a multi-layer coating comprising (i) a polymeric base coat, a chrome adhesion promoting layer, a chromium compound layer, and a layer comprised of a metal compound or metal alloy compound; or (ii) a polymeric base coat, a chromium compound layer, and a layer comprised of a metal compound or metal alloy compound. The layers comprised of chrome, chromium compound and metal compound or metal alloy compound are deposited by vapor deposition, preferably physical vapor deposition.

Abstract: A linear magnetron cathode is disclosed which may be used as a vapor or plasma source for coating deposition or ion processing. The cathode has the shape of an elongated rectangular bar with vaporization of material occurring from an evaporable surface wrapping around the periphery of the bar, along two opposite sides and around both ends. A magnetic field is established over the entire evaporable surface which has a component parallel to the surface and perpendicular to the long direction of the cathode, forming a closed-loop magnetic tunnel around the periphery which directs an arc plasma discharge. Side shields adjacent to sand projecting outward from the sides of the evaporable surface block a significant fraction of the macroparticles ejected from reaching the substrate region. The invention provides uniform cathode erosion and a vaporized material stream in two directions over an extended length, permitting uniform deposition or implantation over large areas.

Abstract: An article is coated with a multi-layer coating comprising a nickel layer, a refractory metal or refractory metal alloy layer, a refractory metal compound or refractory metal alloy compound layer, and a refractory metal oxide or refractory metal alloy oxide layer or a layer comprised of the reaction products of refractory metal or refractory metal alloy, oxygen and nitrogen. The coating is decorative and also provides abrasion protection, corrosion protection, and improved chemical resistance.

Abstract: An apparatus is disclosed for generating oppositely directed streams of plasma for the purpose of depositing a coating or performing ion processing. The plasma comprises ionized vapor of a cathode material, generated by vacuum arc evaporation from a linear magnetron cathode. The plasma is diverted by a deflection electrode to a substrate region, while the macroscopic droplets of cathode material also generated by the arc are intercepted and prevented from reaching the substrate. Magnetic means are disclosed for controlling the arc motion on the cathode surface while simultaneously deflecting and guiding the plasma. The source may be extended indefinitely in length, permitting coating or ion processing of large substrates.

Abstract: A rectangular vacuum-arc plasma source and associated apparatus for generating and directing a stream of plasma containing an ionized vapor of a cathode material toward a substrate by vacuum arc evaporation of a rectangular planar cathode mounted in a rectangular plasma duct. The rectangular duct conducts the plasma from the cathode to the substrate region, while intercepting the molten droplets of cathode material also generated by the arc. Magnets control the arc motion on the cathode surface while simultaneously generating the magnetic field which guides the plasma through the duct. Benefits of a filtered cathodic arc (fully ionized vapor stream, elimination of splattered droplets) are combined with the benefits of a rectangular source (uniform evaporation from the source and uniform deposition on the substrate using linear motion). The rectangular source may be extended indefinitely in length, thus allowing coating or ion implantation on large or long substrates.

Abstract: A rectangular vacuum-arc plasma source and associated apparatus for generating and directing a stream of plasma containing an ionized vapor of a cathode material toward a substrate by vacuum arc evaporation of a rectangular planar cathode mounted in a rectangular plasma duct. The rectangular duct conducts the plasma from the cathode to the substrate region, while intercepting the molten droplets of cathode material also generated by the arc. Magnets control the arc motion on the cathode surface while simultaneously generating the magnetic field which guides the plasma through the duct. Benefits of a filtered cathodic arc (fully ionized vapor stream, elimination of splattered droplets) are combined with the benefits of a rectangular source (uniform evaporation from the source and uniform deposition on the substrate using linear motion). The rectangular source may be extended indefinitely in length, thus allowing coating or ion implantation on large or long substrates.

Abstract: An apparatus and method are described for depositing a coating onto a substrate using vacuum arc evaporation from a substantially cylindrical cathode. An axial magnetic field is disclosed to force the motion of the arc into an open helical trajectory on the cathode surface. Means are also provided for controlling the speed and direction of the arc along the cathode by varying the division of input current between the ends of the cathode. Improved uniformity of cathode erosion and coating thickness are thereby achieved, along with a reduction in the number and size of splattered droplets incorporated into the coating.

Abstract: Highly reflective surfaces, e.g. for headlight reflectors for automotive vehicles can be made by low temperature arc vapor deposition from a mixed metal electrode in which the electrode consists of a mixture of powders of a reflective or relative low melting metal and a ceramic forming high melting metal. The deposit is formed under conditions in which the mixed metals are fully reacted on deposition so that the coating is not susceptible to oxidation in use and requires no protective coating.

Abstract: The formation of an openwork structure e.g., of metal, utilizing low-temperature arc vapor deposition on a foam which is destroyed by pyrolysis is enhanced by applying a portion of the metal in a metal spray of powders in a binder which is also pyrolytically destroyed. The product has essentially the same properties as one made exclusively by the low-temperature arc vapor deposition method.

Abstract: Thermal breakage of crystalline electrodes used in arc-vapor deposition is prevented by originally fabricating the electrodes from broken pieces of the crystalline material which are slightly sintered together and form an electrode body in which a carbon rod or other conductor is embedded to provide electrical contact. The particles are sintered in a vacuum oven and a pool of the electrode material can be formed at a working end of the electrode body when the latter is used for arc-vapor deposition.

Abstract: An openwork nickel structure having a high surface area to volume ratio and a porosity which is largely independent of the degree to which the metal structure may be compressed, is formed by depositing on a pyrolyzable support, preferably a reticulated open-pore polyurethane support, a coating of metal by arc-striking utilizing at least one electrode of that metal and by bringing the electrodes out of contact with one another. The metal-covered support is then subjected to pyrolysis to form the metal skeleton which is then sintered. The resulting metal structure has been found to be suitable for use as an electrode in a Ni-Cd cell.

Abstract: Matrix composites and especially metal matrix composites are formed by coating a foam with a metal or ceramic to form a continuous structure from which the foam material is removed by pyrolysis. If this structure is composed of a metal it is subjected to treatment to transform the metal to a ceramic and the resulting ceramic structure is then filled with another material such as a matrix metal. The product is then compacted and heat treated if desired. The coating of the foam and the filling of the porous ceramic structure are effected preferably by low temperature arc vapor deposition.

Abstract: A method and apparatus for deep penetration deposition of material in a porous substrate utilizes a pressure differential across the substrate to effect penetration of arc-produced vapor from one chamber through the body. The one chamber can be held at a pressure of 10.sup.-2 to 10.sup.-3 torr while the other chamber is at a pressure of 10.sup.-5 to 10.sup.-6 torr.

Abstract: A method and apparatus for deep penetration deposition of material in a porous substrate utilizes a pressure differential across the substrate to effect penetration of arc-produced vapor from one chamber through the body. The one chamber can be held at a pressure of 10.sup.-2 to 10.sup.-3 torr while the other chamber is at a pressure of 10.sup.-5 to 10.sup.-6 torr.

Abstract: Thermal breakage of crystalline electrodes used in arc-vapor deposition is prevented by originally fabricating the electrodes from broken pieces of the crystalline material which are slightly sintered together and form an electrode body in which a carbon rod or other conductor is embedded to provide electrical contact. The particles are sintered in a vacuum oven and a pool of the electrode material can be formed at a working end of the electrode body when the latter is used for arc-vapor deposition.

Abstract: Hard difficult-to-roll alloys are shaped by forming a mold of plastic, especially a polyacrylate, with a highly smooth surface onto which the alloy is deposited by low-temperature arc vapor deposition. The alloy layer is then separated from the plastic substrate and subjected to heat treatment to increase its density.

Abstract: An electric arc vapor deposition apparatus for coating the internal surface of a metal gas-pressure tank has a sealing plug, a means on the plug coupled with a vacuum pump for evacuating the tank, a material-supplying electrode mounted on the plug and an electrical source connectable between the tank and the electrode to supply electric arc energy.

Abstract: Gas-pressure bottles are internally coated by plugging the mouth of the bottle and evacuating the bottle. The coating material is formed by striking repeatedly electric arcs between the electrode deposed within the bottle and the wall of the latter.