OVERCOAT

Abstract

According to embodiments, a method of forming a coating on an article includes forming a coating including an emitting layer. The emitting layer includes an elemental isotope with a known property that can be measured by a spectroscopic method. The elemental isotope provides a distinguishing identification tag for the coating, and the coating providing a layer of protection to the substrate. The method further includes depositing the coating on a surface of a substrate of the article. The elemental isotope is a stable isotope, an unstable isotope, a neutron scattering isotope, a neutron capturing isotope, or combinations thereof.

Description

BACKGROUND

The present disclosure relates protective coatings and, more particularly, to protective coatings that emit, absorb, and/or scatter radiation.

Traditional manufacturing technologies and additive manufacturing (AM) technologies are widely incorporated into defense industry applications. Additive Manufacturing (AM) technologies build three-dimensional (3D) objects by adding layer-upon-layer of material(s). The material(s) can be, for example, plastic, metal, concrete, or biological tissues. AM technologies use a computer, 3D modeling software (Computer Aided Design (CAD)), machinery, and layering material(s). Once a CAD sketch is produced, the AM equipment reads data from a CAD file and disposes successive layers material(s), e.g., liquid, powder, or other sheet material, in a layer-upon-layer fashion to fabricate a 3D object. AM technologies include various subsets, for example, 3D Printing, Rapid Prototyping (RP), Direct Digital Manufacturing (DDM), layered manufacturing, and additive fabrication.

The widespread incorporation of traditional manufacturing and AM technologies in the defense industry means that there needs to be some measures to ensure that parts of the supply chain are in optimal condition. Furthermore, the drive for extending the life of defense related products creates opportunities to have worn parts slipped into the supply chain.

SUMMARY

According to embodiments, a method of forming a coating on an article includes forming a coating including an emitting layer. The emitting layer includes an elemental isotope with a known property that can be measured by a spectroscopic method. The elemental isotope provides a distinguishing identification tag for the coating, and the coating providing a layer of protection to the substrate. The method further includes depositing the coating on a surface of a substrate of the article. The elemental isotope is a stable isotope, an unstable isotope, a neutron scattering isotope, a neutron capturing isotope, or combinations thereof.

According to other embodiments, a method of determining a need for performing preventative maintenance on an article includes performing a spectroscopic analysis on a portion of the article including a coating. The coating includes an emitting layer. The emitting layer includes an elemental isotope that can be measured by the spectroscopic analysis, and the coating provides a layer of protection to the substrate. The method further includes comparing a signal received from the spectroscopic analysis to a calibration curve. The method further includes determining, based on a comparison, whether the coating protecting the substrate has been worn and therefore whether the article needs maintenance. The elemental isotope is a stable isotope, an unstable isotope, a neutron scattering isotope, a neutron capturing isotope, or combinations thereof.

Yet, according to other embodiments, a coating of an article includes an emitting layer arranged on a substrate of the article. The emitting layer includes an elemental isotope with a known property that can be measured by a spectroscopic method. The elemental isotope provides a distinguishing identification tag for the coating, and the coating provides a layer of protection to the substrate. The coating further includes an attenuating layer arranged on the emitting layer. The attenuating layer protects the emitting layer. The elemental isotope is a stable isotope, an unstable isotope, a neutron scattering isotope, a neutron capturing isotope, or combinations thereof.

Additional features and advantages are realized through the techniques of the present invention. Other embodiments and aspects of the invention are described in detail herein and are considered a part of the claimed invention.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

For a more complete understanding of this disclosure, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts:

FIG. 1 is a cross-sectional side view of an emitting layer of a coating arranged on a substrate according to embodiments;

FIG. 2 is a cross-sectional side view of an emitting layer of a coating decaying according to embodiments;

FIG. 3 is a cross-sectional side view of an emitting layer of a coating emitting a gamma ray according to embodiments;

FIG. 4 is a cross-sectional side view of an emitting layer of a coating according to embodiments;

FIG. 5 is a cross-sectional side view of a coating comprising an attenuating layer arranged on an emitting layer according to embodiments;

FIG. 6 is a cross-sectional side view illustrating wear occurring to a coating according to embodiments;

FIG. 7 is a flow chart describing a method of identifying characteristics of an article using a coating according to embodiments;

FIG. 8 is a flow chart describing a method of determining a need for performing preventative maintenance using a coating according to embodiments; and

FIG. 9 is a flow chart describing a method of passively aging a coating according to embodiments.

DETAILED DESCRIPTION

As will be discussed below, embodiments disclosed herein provide methods for forming protective coatings on a variety of substrates. In embodiments, methods described herein use the coatings to identify and age components safely and effectively for use domestically and abroad. In some embodiments, specific blends of isotopes, e.g., stable and/or unstable, that differ from that naturally occurring abundance ratios can be used in the coating to identify the part lot, manufacturer, etc. In other embodiments, gamma emitting radio-isotopes, x-ray emitting radio-isotopes, or neutron scattering isotopes are admixed as nanoparticles into a bulk overcoating material.

In embodiments, using thermal and cold spray methodologies, the nanoparticles form hard undercoat that can be protected by an optional top attenuating or scattering coat. Still, in other embodiments, the coating can be a paint layer or powder coat layer, in which the nanoparticles are homogenously mixed throughout one or more overcoat layers to serve a protective monolayer for underlying hardware. The resulting coatings improve resistance to damage, such as corrosion and wear.

In embodiments, the coating is used to determine the need for preventative maintenance, for example, when it is desired to service a component on a regular interval regardless of wear. The coatings described herein are advantageous because the amount of coating wear correlates with the the age of the coating. Therefore, the coating can be passively aged to determine the amount of coating wear, and therefore on the article. Many applicable to items have a life limit (expiration date) regardless of wear. Identifying heavy wear on components is particularly useful for military and defense part applications, as well as in commercial applications.

Turning now to the Figures, FIG. 1 is a cross-sectional side view of an emitting layer 102 of a coating arranged on a surface of a substrate 101 according to embodiments. The coating protects the substrate 101 of the article. The substrate 101 can include any bulk material. The substrate 101 shown is not drawn to size, shape, or scale, and is only shown for illustrative purposes. The substrate 101 is intended to be a part or whole of any type of article. The substrate 101 can be formed by any suitable methods, for example, traditional manufacturing methods or AM. The substrate 101 is part of a microchip and integrated circuit in embodiments. In other embodiments, the substrate 101 can form part of an article (or device), such as an optical device, turbine engine fan blade, detector, or any other device, for example. While such elements are given as examples herein, the techniques and methods disclosed herein may be used, in whole or in part, with many materials whether it is electrically active or not. The material or materials forming the substrate 101 are not limited to any particular type or property. In some exemplary embodiments, the substrate 101 includes one or more of a conductive material, a semiconductor material, or an insulating material. The substrate 101 can be an article used in the defense sector, for example, wherein preventative maintenance with respect to wearing and corrosion is routinely performed. The substrate 101 also can be an article used in the commercial sector. In exemplary embodiments, the substrate 101 can be part of a car engine, such as a part of the inside of a piston. Although, the substrate 101 is not limited to these examples.

The coating on the substrate 101 can include a single emitting layer 102. The emitting layer 102 can also include one or more layers. The emitting layer 102 of the coating includes elemental isotopes with known properties that can be measured an analyzed by a spectroscopic method. The emitting layer 102 includes one or more of a stable isotope, a gamma ray emitting isotope, an x-ray emitting isotope, a neutron scattering isotope, neutron capturing isotope, or a combination thereof, which will be described in further detail below. The isotopes provide a unique signature, or a distinguishing identification tag for the coating that may be observed by various atomic level measurement techniques, for example, mass spectrometry, a gamma ray spectroscopy, scintillation detection, or neutron spectroscopy.

The emitting layer 102 forms a base coating layer directly on the substrate 101 according to one or more embodiments. In other embodiments, intermediate layers are formed between the substrate 101 and the emitting layer 102 (not shown). The emitting layer 102 includes particles that are micron-sized or nano-sized emitting particles. The particles may stand alone, being deposited directly onto the substrate 101 to form the entire emitting layer 102, or may be mixed with a metal binder to form a powder.

The emitting layer 102 can be formed by any desired method, which depends on the substrate 101, desired properties of the coating, and the particular use of the substrate 101. Examples of methods for forming the emitting layer 102 include, but are not limited to, painting, powder coating, primer methods, epoxy methods, RTV methods, thermal spraying, cold spraying, vapor deposition, liquid deposition, and electrolytic coating methods.

The emitting layer 102 is thick enough or thin enough such that it covers an entire surface (or in some cases limited to a critical feature/surface) of the substrate 101. The thickness of the emitting layer 102 generally varies and is not intended to be limited. The thickness of the emitting layer 102 is tailorable and depends on the amount of time that the emitting layer 102 is desired to be maintained. According to one or more embodiments, the emitting layer 102 is an atomic monolayer. The emitting layer 102 can be very thick, depending on the application, and therefore, the thickness of the emitting layer 102 is not intended to be limited. The emitting layer 102 does not have to be a uniform thickness, and in some embodiments, the emitting layer 102 has a non-uniform thickness.

As mentioned above, cold spraying is one method of forming the emitting layer 102. Briefly, the cold spray process includes dispensing a powder of micron-sized or nano-sized emitting particles into a feeder of a cold spray machine. The particles can stand alone or be coated with a metal binder to form a micron-sized powder. The particles are combined with pressurized gas and accelerated at a high velocity, such as about 500-1500 m/s, and a low temperature, such as about 100 to 550° C., at a substrate. The high velocity allows for plastic deformation to adhere the particles to the substrate, forming a coating of the emitting layer 102.

FIG. 2 is a cross-sectional side view of an emitting layer 102 of a coating decaying according to embodiments. The emitting layer 102 emits a signal 210 that is measured and detected by analytical spectroscopic methods, depending on the composition of the emitting layer 102. The emitting layer 102 includes stable isotopes, unstable isotopes, or blends of stable and/or unstable isotopes in some embodiments. In other embodiments, the emitting layer 102 includes one or more unstable isotopes, such as a gamma ray emitting isotope, or a blend of gamma ray emitting isotopes. Yet, in other embodiments, the emitting layer 102 includes one or more neutron capturing or scattering isotopes.

The signal 210 can be an isotopic signature that is detected by mass spectrometry, for example. Unique isotopic signatures can be used as a distinguishing identification tag that indicates a property of the coating such as where the coating was made (a source of the coating or the manufacturer), when the coating was made, and/or what the coating includes, for example. The unique isotopic signature can also provide a means of identifying information about the part, such as the serial number, model number, etc. The isotopic signature can be made unique and identifiable by altering the ratio of stable and unstable isotopes.

The nucleus of each atom of an element includes protons and neutrons. The number of protons defines the element (e.g., hydrogen, carbon, etc.), and the sum of the protons and neutrons provides the atomic mass. The number of neutrons defines the isotope of that element. For example, most carbon (≈99%) has 6 protons and 6 neutrons and is written as ¹²C to reflect its atomic mass. However, about 1% of the carbon in the Earth's biosphere has 6 protons and 7 neutrons (¹³C), forming the heavy stable isotope of carbon. Stable isotopes of an element do not decay into other elements. In contrast, radioactive isotopes (e.g., ¹⁴C) are unstable isotopes and will decay into other elements.

The less abundant stable isotope(s) of an element have one or two additional neutrons than protons, and thus are heavier than the more common stable isotope for those elements. Both heavy and light stable isotopes participate freely in chemical reactions and in biological and geochemical processes. However, the rate at which heavy and light stable isotopes react during physical or chemical reactions differs. The chemical bonds and attractive forces of atoms with heavy stable isotopes are stronger than those in the more common, lighter isotopes of an element. As a result, the heavier isotopes react more slowly than the lighter isotopes, leading to isotopic separation or fractionation between reactant and product in both physical and biological reactions. Fractionation of the heavy and light stable isotopes is important because it produces variation in the stable isotope ratio of different element pools and establishes an isotopic signal that can indicate the existence or magnitude of key processes involved with elemental cycling.

The isotopic signature, and signal 210, including the relative frequencies of stable and unstable isotopes, of an element can be artificially augmented in the emitting layer 102. The ratio of the isotopes can be determined by mass spectrometry, for example. The isotopic signature of the emitting layer can be altered by introducing a combination of synthetic stable and unstable isotopic variations of an element, such as, for example, americium, polonium, plutonium, carbon, or a combination thereof. Stable isotopes can be used in combination with unstable isotopes, as described below in FIG. 3.

To use the coating as a distinguishing identification tag for the article, spectroscopic analysis is performed on the coating. The signal (or spectral feature) received from the analysis is compared to a known signal (or spectral feature) of the coating that is known and determined at the time of original formation of the coating on the article. The comparison provides unique identifying information about the coating and therefore the article itself.

FIG. 3 is a cross-sectional side view of an emitting layer 102 of a coating emitting a gamma ray 310 according to embodiments. The gamma ray 310 results from emission, or decay, of an unstable or metastable isotope of an element, with a characteristic fraction of events emitting gamma rays 310 of a specific energy. The unstable or metastable isotope is an emissive tag for the coating.

The gamma ray 310 emitting isotopes may be relatively short-lived radioactive isotopes and may be added in just about any amount, provided that they provide useful emission rates and safe handling. According to one or more embodiments, the gamma ray emitting isotope may be added in a range of parts per million to fractional parts per billion. Each isotope may produce a characteristic energy (or energies) for the photons emitted. It is this spectral character of the outputs that allows identification of specific nuclear material that is in the item. The unique spectrum can be analyzed using, for example, a scintillation detector or another radiation detector. Some non-limiting examples of gamma ray 310 emitting isotopes include Barium-133, Calcium-109, Cobalt-57, Europium-152, Manganese-54, Sodium-22, Lead-210, and Zinc-65.

FIG. 4 is a cross-sectional side view of a layer 402 of a coating according to embodiments. The layer 402 includes a neutron 410 scattering and/or a neutron absorbing/capturing element. The neutron 410 scattering or capturing element can be, but is not limited to, Boron¹⁰, Erbium, Gadolinium, Molybdenum, Titanium, Ytterbium, Cadmium, Dysprosium, Europium, Hafnium, Samarium, or Xenon.

When layer 402 is bombarded with neutrons 410, the layer 402 captures or scatters the neutrons. Analysis can be performed to determine the layer thickness of an attenuating layer having a known chemical composition. Understanding the part substrate material composition and thickness, the emitting layer composition and thickness, and then the composition of the attenuating layer will allow the calculation of the thickness of the attenuating layer. Such analysis could be performed, for example, with a Monte-Carlo simulation, such as Los Alamos National Lab's Monte Carlo Neutral Particle analysis tool. When such an analysis is performed, backscattering is also considered. The radiated layer scatters into the actual part and then reflects back to the detector, and therefore, a combination of direct impingement, scatter, and backscatter are being detected. In order to accurately determine the thickness of the layer 402, the material forming the part are known in fine detail, including the source layer, and substrate chemical composition and thickness.

FIG. 5 is a cross-sectional side view of a coating comprising an attenuating layer 503 arranged on an emitting layer 102 according to embodiments. One or more attenuating layers 503 are included in the coating. The attenuating layer 503 protects the emitting layer 102 and the substrate 101 from general wear and tear, and although not required, may be desirable. Even when an attenuating layer 503 is present on the emitting layer 102, emission from a radioactive element emitting a signal 510 in the emitting layer 102 can still be detected. According to one or more embodiments, the attenuations layer 503 is a pristine attenuating layer, with high attenuation.

The attenuating layer 503 can include one or more layers that are the same or different. The composition of the attenuating layer 503 depends on the composition of the emitting layer 102. The attenuating layer 503 can include a micron sized or nano sized metallic powder with attenuating characteristics, for example. The attenuating layer 503 can also have gamma ray or neutron capturing properties. Other non-limiting examples of materials for the attenuating layer 503 include Teflon, lacquers, plastics, paints, or a combination thereof.

FIG. 6 is a cross-sectional side view illustrating wear occurring in the attenuating layer 503 of a coating according to embodiments. The attenuating layer 503 is a damaged/worn attenuating layer, with low attenuation.

The crack 602 is shown to generally illustrate the wear and tear that can occur. As the attenuating layer 503 becomes worn, or cracked, a stronger signal 510 from the emitting layer 102 will be detected. The signal indicates the degree of wear on the attenuating layer 503 and can serve as a warning that the device is in need of preventative maintenance.

When the coating is used to determine a need for preventative maintenance, a spectroscopic analysis is performed on a portion of the article comprising the coating. Spectroscopic methods allow enable isolation of signals from sources selected for the coating, which serves as a method rejecting noise from background radiation sources. The resulting signal of all the primary and any secondary daughter products is compared to the “as manufactured” data, and an assessment for attenuating layer thickness is possible. For example, a signal received from the spectroscopic analysis is compared to a known signal, such as a calibration curve. Based on the comparison, it is then determined whether the coating protecting the substrate has been worn and therefore whether the article needs to be replaced or needs maintenance.

In embodiments in which an attenuating layer 503 is included in the coating, a signal received from the spectroscopic analysis increases as the attenuating layer wears and thins.

Any of the above embodiments described in FIGS. 1-6 can be employed independently or in combination with one another to form the coating described herein. Furthermore, any of the embodiments of the coatings described in FIGS. 1-6 can be employed with the following methods described in FIGS. 7-9. For example, stable isotopes, unstable isotopes (e.g., gamma ray emitters), and/or neutron scattering/capturing elements can be included in the coating.

FIG. 7 is a flow chart describing a method of identifying characteristics of an article using a coating according to embodiments. In box 702, a substrate is provided. As described above, the substrate can include any one or more materials and can form a part of any article. In box 704, a coating is formed on the substrate. Any of the coatings described in FIGS. 1-6 can be employed independently or in combination. In box 706, the coated substrate 706 is put into a manufacturing supply chain, which can be used to manufacture a larger part or device. Alternatively, the substrate itself may be entirely coated with the coating to form a final article. In box 708, an atomic level property of the coating is measured and analyzed, for example, by a spectroscopic method. In box 710, characteristics of the substrate are identified, such as the source of the substrate, the lot, the manufacturer, etc.

A method of identifying characteristics of an article using the coating is described as follows according to an exemplary embodiment. On the day of creation the coating will have a detectable spectral signal and baseline intensity. The signal intensity for each radiating isotope decreases exponentially with time, commonly referred to as the half-life. Various methods can be employed for forming the coating. For example, according to some embodiments, the coating can be doped with a long-lived isotope with half-life, A, and a second dopant with a shorter half-life, B, which is scaled to the intended useful life of the product or coating. B should be much larger than A. In this fashion, B is a control for the decay of A, and A is indicative of layer age. However, A also should be long-lived, as well as deeply penetrating (high energy), so that it can freely pass through attenuating layers so that the attenuating layers do not affect the aging calculation. Subsequently, the high intensity B can be measured, and knowing its calibration baseline, the emitted versus calculated can then be compared. The differences are attributed to the wear of the layer. One or both of the dopants are thus useful in determining wear of coating. Both are useful in the identification of the product as an isotopic “fingerprint,” which changes through time when referenced to the baseline as-created state. As the number of emitting isotopes is increased, and initialized concentration variation is controlled, this “fingerprint” is further strengthened and becomes much more complicated to spoof.

FIG. 8 is a flow chart describing a method of determining a need for performing preventative maintenance using a coating according to embodiments. In box 802, a substrate is provided. As described above, the substrate can include any one or more materials and can form a part of any device. In box 804, a coating is formed on the substrate. Any of the coatings described in FIGS. 1-6 can be employed independently or in combination. In box 806, the coated substrate is put into operation, alone or as part of a larger article. In box 808, an atomic level property of the coating is measured and analyzed, for example, by a spectroscopic method. In box 810, the degree of wear on the substrate is determined.

FIG. 9 is a flow chart describing a method of passively aging a coating according to embodiments. In box 902, a substrate is provided. As described above, the substrate can include any one or more materials and can form a part of any article. In box 904, a coating is formed on the substrate. Any of the coatings described in FIGS. 1-6 can be employed independently or in combination. In box 906, the coated substrate is put into operation, alone or as part of a larger article. In box 908, the age of the coating is determined.

The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiments were chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.

While the preferred embodiments to the invention have been described, it will be understood that those skilled in the art, both now and in the future, may make various improvements and enhancements which fall within the scope of the claims which follow. These claims should be construed to maintain the proper protection for the invention first described.

Claims

1. A method of forming a coating on an article, the method comprising:

forming a coating comprising an emitting layer, the emitting layer comprising an elemental isotope with a known property that can be measured by a spectroscopic method, the elemental isotope providing a distinguishing identification tag for the coating, and the coating providing a layer of protection to the substrate; and

depositing the coating on a surface of a substrate of the article;

wherein the elemental isotope is a stable isotope, an unstable isotope, a neutron scattering isotope, a neutron capturing isotope, or combinations thereof.

2. The method of claim 1, wherein the coating is deposited by a cold spraying method.

3. The method of claim 1, wherein the coating is deposited by painting, powder coating, primer method, epoxy method, RTV method, thermal spraying, vapor deposition, liquid deposition, electrolytic coating, or a combination thereof.

4. The method of claim 1, wherein the coating further includes an attenuating layer disposed on the emitting layer that protects the emitting layer.

5. The method of claim 1, wherein the elemental isotope is an unstable isotope.

6. The method of claim 5, wherein the unstable isotope is a gamma ray emitting isotope.

7. The method of claim 1, wherein the coating comprises micron-sized particles or nano-sized particles comprising the elemental isotope.

8. The method of claim 1, wherein the elemental isotope is a blend of stable and unstable isotopes of an element that differs from a natural abundance.

9. The method of claim 1, wherein the spectroscopic method is mass spectrometry, radiation detection, or a combination thereof.

10. The method of claim 1, wherein the distinguishing identification tag indicates where the coating was made, when the coating was made, what the coating comprises, provides identifying information, or a combination thereof.

11. A method of determining a need for preventative maintenance on an article, the method comprising:

performing a spectroscopic analysis on a portion of the article comprising a coating, the coating comprising an emitting layer, the emitting layer comprising an elemental isotope that can be measured by the spectroscopic analysis, and the coating providing a layer of protection to the substrate;

comparing a signal received from the spectroscopic analysis to a calibration curve; and

determining, based on a comparison, whether the coating protecting the substrate has been worn and therefore whether the article needs maintenance;

wherein the elemental isotope is a stable isotope, an unstable isotope, a neutron scattering isotope, a neutron capturing isotope, or combinations thereof.

12. The method of claim 11, wherein the elemental isotope is an emissive tag.

13. The method of claim 12, wherein the emissive tag is a gamma ray emitting isotope.

14. The method of claim 13, wherein the coating comprises micron-sized particles or nano-sized particles comprising the elemental isotope.

15. The method of claim 11, wherein the coating further comprises an attenuating layer arranged on the emitting layer.

16. The method of claim 15, wherein the attenuating layer protects the emitting layer, and the signal received from the spectroscopic analysis increases as the attenuating layer wears and exposes the emitting layer.

17. A coating of an article, comprising:

an emitting layer arranged on a substrate of the article, the emitting layer comprising an elemental isotope with a known property that can be measured by a spectroscopic method, the elemental isotope providing a distinguishing identification tag for the coating, and the coating providing a layer of protection to the substrate; and

an attenuating layer arranged on the emitting layer, the attenuating layer protecting the emitting layer;

wherein the elemental isotope is a stable isotope, an unstable isotope, a neutron scattering isotope, a neutron capturing isotope, or combinations thereof.

18. The coating of claim 17, wherein the emitting layer comprises micon sized or nano sized emitting particles.

19. The coating of claim 18, wherein the attenuating layer comprises micron sized or nano sized particles.

20. The coating of claim 17, wherein the emitting layer comprises gamma ray emitting particles or x-ray emitting particles.