Abstract: A valve for an anti-lock brake system, wherein the anti-lock brake system is configured for controlling flow of a fluid, includes a housing defining a cavity therein and having a longitudinal axis, a valve seat disposed within the cavity so as to define a first passage for the fluid, and an armature disposed within the cavity so as to at least partially define a second passage for the fluid. The armature is translatable with respect to the valve seat along the longitudinal axis and matable with the valve seat to seal off fluid communication between the first passage and the second passage. The armature defines a surface that is substantially resistant to corrosion from the fluid, and the surface is substantially free from a coating including zinc.

Abstract: A neodymium magnet (Nd—Fe—B) is protected by a self-healing, corrosion-resistant coating of (a) a sacrificial metal layer; (b) optionally, a metal pretreatment layer on the sacrificial metal layer; and (c) an electrocoat coating layer.

Abstract: A system for electro-coating a metallic substrate includes a DC power supply, a primary electrode, and a wireless auxiliary electrode. The primary electrode transmits electrical current through electrolyte fluid when energized by the power supply. The auxiliary electrode is within the drain hole, and receives the current from the fluid at one end. The auxiliary electrode boosts the calibrated voltage at the opposite end near the drain hole. In a method for depositing thin film material onto the internal surfaces, the wireless auxiliary electrode is positioned in the drain hole, and the calibrated voltage is applied from the DC power supply to the primary electrode. Electrical current transmitted through the fluid is received at the first end of the auxiliary electrode. The calibrated voltage is boosted in proximity to the drain hole at the second end of the same auxiliary electrode. A wireless auxiliary electrode assembly is also provided.

Abstract: A valve for an anti-lock brake system, wherein the anti-lock brake system is configured for controlling flow of a fluid, includes a housing defining a cavity therein and having a longitudinal axis, a valve seat disposed within the cavity so as to define a first passage for the fluid, and an armature disposed within the cavity so as to at least partially define a second passage for the fluid. The armature is translatable with respect to the valve seat along the longitudinal axis and matable with the valve seat to seal off fluid communication between the first passage and the second passage. The armature defines a surface that is substantially resistant to corrosion from the fluid, and the surface is substantially free from a coating including zinc.

Abstract: A system for electro-coating a metallic substrate includes a DC power supply, a primary electrode, and a wireless auxiliary electrode. The primary electrode transmits electrical current through electrolyte fluid when energized by the power supply. The auxiliary electrode is within the drain hole, and receives the current from the fluid at one end. The auxiliary electrode boosts the calibrated voltage at the opposite end near the drain hole. In a method for depositing thin film material onto the internal surfaces, the wireless auxiliary electrode is positioned in the drain hole, and the calibrated voltage is applied from the DC power supply to the primary electrode. Electrical current transmitted through the fluid is received at the first end of the auxiliary electrode. The calibrated voltage is boosted in proximity to the drain hole at the second end of the same auxiliary electrode. A wireless auxiliary electrode assembly is also provided.

Abstract: Some articles such as automobile components that have been constructed from steel and/or aluminum alloy parts are now being fitted with magnesium parts whose surfaces may need to be protected against corrosion. To do this an e-coating pre-film may be formed on the part's magnesium surfaces by exposing it to a conventional e-coating emulsion. And there is no need to supply a current or potential to the part or component. Magnesium's high reactivity with acidic or neutral aqueous mediums is itself a sufficient driving force to facilitate the deposition of an e-coating pre-film. At the same time any steel or aluminum alloy parts will remain unaffected. The article with a protective e-coating pre-film formed solely on its magnesium surfaces may now be advanced through a paint-line that includes conventional processes aimed at treating the component's steel and aluminum alloy parts. The process may be practiced where the magnesium surface comprises a magnesium-containing conversion or anodized coating.

Abstract: Mixed-metal automotive vehicle bodies-in-white comprising ferrous metal surfaces, zinc surfaces, aluminum alloy surfaces, and magnesium alloy surfaces are cleaned and immersed in an aqueous bath comprising an adhesion promoter and an aqueous electrocoat bath (the adhesion promoter may be in the electrocoat bath. The adhesion promoter, which may be a cerium salt, is selected to react with each metal in the body surfaces to form an oxide layer that provides corrosion resistance for the surface and adherence for the deposited polymeric paint coating. The body is cathodic in the electrocoat deposition.

Abstract: A method is disclosed for high volume production of molded dimensionally accurate polymer composite articles comprising three-dimensional carbon fiber reinforcement in high volume. Carbon fiber cloth infiltrated with a liquid thermosetting polymer precursor is shaped by application of pressure to urge the cloth against the surface of a mold and then heated while under pressure to cure the polymer precursor into a solid polymeric matrix for the carbon fiber article. Mold tooling is formed of suitable iron-nickel alloys and provided with a hard electroless nickel coating on the mold cavity surface. The iron and nickel alloy provides thermal expansion properties generally matched to those of the articles for the molding of dimensionally accurate parts.

Abstract: An electrode assembly for use with an electrodeposition process. According to an exemplary embodiment, the electrode assembly includes an electrode for exchanging electrical current with a solution, a passageway for removing gas that becomes trapped between a workpiece and the solution, and a sleeve for electrically isolating the electrode from the workpiece.

Abstract: In one exemplary method, an anodized aluminum-silicon alloy work piece may be formed from an aluminum-silicon alloy substrate material by applying a friction stir processing treatment to the aluminum-silicon alloy substrate material to reduce an average particle size of a plurality of silicon particles contained within the substrate material while increasing a size uniformity of the plurality of silicon particles, and subsequently anodizing said aluminum-silicon alloy substrate material.

Abstract: Mixed-metal automotive vehicle bodies-in-white comprising ferrous metal surfaces, zinc surfaces, aluminum alloy surfaces, and magnesium alloy surfaces are cleaned and immersed in an aqueous bath comprising an adhesion promoter and an aqueous electrocoat bath (the adhesion promoter may be in the electrocoat bath. The adhesion promoter, which may be a cerium salt, is selected to react with each metal in the body surfaces to form an oxide layer that provides corrosion resistance for the surface and adherence for the deposited polymeric paint coating. The body is cathodic in the electrocoat deposition.

Abstract: An electrode assembly for use with an electrodeposition process. According to an exemplary embodiment, the electrode assembly includes an electrode for exchanging electrical current with a solution, a passageway for removing gas that becomes trapped between a workpiece and the solution, and a sleeve for electrically isolating the electrode from the workpiece.

Abstract: Some articles such as automobile components that have been constructed from steel and/or aluminum alloy parts are now being fitted with magnesium parts whose surfaces may need to be protected against corrosion. To do this an e-coating pre-film may be formed on the part's magnesium surfaces by exposing it to a conventional e-coating emulsion. And there is no need to supply a current or potential to the part or component. Magnesium's high reactivity with acidic or neutral aqueous mediums is itself a sufficient driving force to facilitate the deposition of an e-coating pre-film. At the same time any steel or aluminum alloy parts will remain unaffected. The article with a protective e-coating pre-film formed solely on its magnesium surfaces may now be advanced through a paint-line that includes conventional processes aimed at treating the component's steel and aluminum alloy parts. The process may be practiced where the magnesium surface comprises a magnesium-containing conversion or anodized coating.

Abstract: Die casting of some magnesium alloys may yield castings that are susceptible to corrosion when exposed to salt water or other aggressive oxidizing environments. Such corrosion may result from the existence of different microstructures in a cross-section of the die casting (e.g. between the surface of the part and the center) that produce galvanic couples that are susceptible to such corrosive attack. However, a die temperature may be determined for casting of the part such that a more uniform cross-sectional microstructure is produced in which minimal or negligible galvanic potentials are produced.

Abstract: Mold tooling formed of suitable iron-nickel alloys and provided with a hard electroless nickel coating on the mold cavity surface are useful for high volume production of carbon fiber reinforced, polymer matrix, composites. The iron and nickel alloy provides thermal expansion properties for the molding of dimensionally accurate parts. The nickel alloy coating provides a durable surface, without adversely affecting the expansion properties of the mold, and remains adherent to the base metal during the repeated thermal cycling encountered in high volume production of substantially identical molded carbon composite parts.

Abstract: Durable elastomeric polyurea coatings can be applied to metal surfaces subjected to impacts and environmental corrosion. Corrosion resistance of the coatings, especially on magnesium alloy surfaces, is improved by incorporation of particulate inhibitor additives in the liquid polyurea precursor coating material. Examples of inhibitors include potassium dichromate, sodium dichromate, potassium permanganate, vanadium pentoxide, phosphorus anhydride, cerium oxide, lanthanum oxide, calcium oxide and sodium oxide.

Abstract: The present invention uses a two-step anodizing process to produce a colored anodized coating on the surface of an aluminum part. In accordance with this invention, a thin hard anodized coating layer is first formed on the surface of the aluminum part and then growing a softer a clear anodized coating layer on the surface of the aluminum part underneath the hard coat layer. The soft coat is essentially colorless and suitable for color finishing. This invention drastically improves the wear resistance of the aluminum part while maintaining a desired amount of clarity for effective electrolytic coloring.

Abstract: A process is disclosed for stabilizing certain colored anodized coating on aluminum articles against degradation by ultraviolet radiation. Anodized articles colored by an electrolytic or interference process can thereafter be stabilized by heat treating them at temperatures of the order of 350° F. for a period of an hour or so. The process is particularly useful for use on electrolytically colored, anodized vehicular external body panels made from suitably formable sheet metal aluminum alloys.

Abstract: A process is disclosed for stabilizing certain colored anodized coating on aluminum articles against degradation by ultraviolet radiation. Anodized articles colored by an electrolytic or interference process can thereafter be stabilized by heat treating them at temperatures of the order of 350° F. for a period of an hour or so. The process is particularly useful for use on electrolytically colored, anodized vehicular external body panels made from suitably formable sheet metal aluminum alloys.

Abstract: Pistons reciprocating in cylinders of a hydrocarbon-fueled internal combustion engine tend to trap air and unburned fuel between the top of the piston head and its enclosing cylinder wall. The circumferential side surface (or land) of the piston head above its upper piston ring groove is provided with a thin coating of porous aluminum oxide. Particles of an oxidation catalyst for the engine's fuel are electrolytically deposited in the pores of the oxide coating. During engine operation the oxide-supported catalyst particles promote combustion of the entrained fuel.