PREPARATION OF A MOLYBDENUM-SILICON- PHOSPHORUS-TRANSITIONAL METAL COMPOSITE COATING BATH AND PROCESS FOR ZINC-NICKEL PLATING

Abstract

A method of disposing a corrosion resistant system to a substrate is disclosed. The method includes applying a plating material to the substrate, forming a chemical conversion coating solution by combining a solvent, at least one corrosion inhibitive cation comprising at least one of zirconium, titanium, cerium, vanadium species, manganese, or niobium, and at least one corrosion inhibitive anion comprising at least one of phosphate, molybdate, or silicate, and applying the chemical conversion coating solution to the plating material on the substrate.

Claims

1. A method of disposing a corrosion resistant system to a substrate, comprising: applying a plating material to the substrate; forming a chemical conversion coating solution by combining a solvent, at least one corrosion inhibitive cation comprising at least one of zirconium, titanium, cerium, vanadium species, manganese, or niobium, and at least one corrosion inhibitive anion comprising at least one of phosphate, molybdate, or silicate; and applying the chemical conversion coating solution to the plating material on the substrate.

2. The method of claim 1, further comprising: prior to applying the chemical conversion coating solution to the plating material on the substrate, activating the plating material with an activator, wherein the activator is at least one of nitric acid or alkaline immersion cleaner.

3. The method of claim 2, further comprising: prior to activating the plating material with an activator, degreasing the plating material on the substrate, wherein the plating material on the substrate is degreased with at least one of acetone or methyl acetate.

4. The method of claim 1, wherein the chemical conversion coating solution is applied to the plating material on the substrate by dipping the substrate plated with the plating material into a bath of the chemical conversion coating solution for between 2 minutes to 20 minutes, wherein the chemical conversion coating solution comprises at least one complexing agent, at least one oxidizer, and at least one organic polymer additive, wherein the at least one complexing agent is at least one of sulfuric acid, nitric acid, a fluorosilicic acid solution, Ethylenediaminetetraacetic acid (EDTA), tartaric acid, oxalic acid, phytic acid, citric acid, or glycine, wherein the at least one oxidizer is at least one of hydrogen peroxide (H.sub.2O.sub.2) or a permanganate compound, and wherein the at least one polymer additive is at least one of tannic acid, polyacrylic acid, polyvinyl alcohol, or polyvinylpyrrolidone.

5. The method of claim 1, further comprising: drying the substrate plated with the plating material and coated with a chemical conversion coating for at least two hours at between 30 C. (86 F.) and 200 C. (392 F.).

6. The method of claim 1, wherein the chemical conversion coating solution has a pH of between 3.5 and 12.

7. The method of claim 1, further comprising: forming a corrosion inhibition composition solution by combining at least one of phosphate, molybdate, or silicate; and applying the corrosion inhibition composition solution to the substrate plated with the plating material and coated with a chemical conversion coating.

8. The method of claim 7, wherein the corrosion inhibition composition solution is applied to the substrate plated with the plating material and coated with the chemical conversion coating on by dipping the substrate plated with the plating material and coated with the chemical conversion coating into a bath of the corrosion inhibition composition solution for between 3 minutes to 12 minutes.

9. The method of claim 7, further comprising: drying the substrate plated with the plating material, coated with the chemical conversion coating, and coated with a corrosion inhibition composition coating for at least two hours at between 30 C. (86 F.) and 200 C. (392 F.).

10. A corrosion inhibition system disposed on a substrate, comprising: the substrate; a plating material disposed on the substrate; and a chemical conversion coating disposed on the plating material and comprising a corrosion inhibitive cation comprising at least one of zirconium, titanium, cerium, vanadium species, manganese, or niobium, and a corrosion inhibitive anion comprising at least one of phosphate, molybdate, or silicate.

11. The corrosion inhibition system of claim 10, comprising: an activator applied to the plating material prior to disposing the chemical conversion coating disposed on the plating material, the activator being at least one of nitric acid or alkaline immersion cleaner.

12. The corrosion inhibition system of claim 11, wherein the plating material is degreased prior to disposing the activator on the plating material and wherein the plating material on the substrate is degreased with at least one of acetone or methyl acetate.

13. The corrosion inhibition system of claim 10, wherein the chemical conversion coating is applied to the plating material on the substrate by dipping the substrate plated with the plating material into a bath of a chemical conversion coating solution for between 2 minutes to 20 minutes, wherein the chemical conversion coating solution comprises at least one complexing agent, at least one oxidizer, and at least one organic polymer additive, wherein the at least one complexing agent is at least one of sulfuric acid, nitric acid, a fluorosilicic acid solution, Ethylenediaminetetraacetic acid (EDTA), tartaric acid, oxalic acid, phytic acid, citric acid, or glycine, wherein the at least one oxidizer is at least one of hydrogen peroxide (H.sub.2O.sub.2) or a permanganate compound, and wherein the at least one polymer additive is at least one of tannic acid, polyacrylic acid, polyvinyl alcohol, or polyvinylpyrrolidone.

14. The corrosion inhibition system of claim 10, wherein the substrate is plated with the plating material and coated with the chemical conversion coating is dried for at least two hours at between 30 C. (86 F.) and 200 C. (392 F.).

15. The corrosion inhibition system of claim 10, wherein the chemical conversion coating has a pH of between 3.5 and 12.

16. The corrosion inhibition system of claim 10, further comprising: a corrosion inhibition composition coating disposed on the chemical conversion coating and comprising at least one of phosphate, molybdate, or silicate.

17. The corrosion inhibition system of claim 16, wherein the corrosion inhibition composition coating is applied to the substrate plated with the plating material and coated with the chemical conversion coating on by dipping the substrate plated with the plating material and coated with the chemical conversion coating into a bath of a corrosion inhibition composition solution for between 3 minutes to 12 minutes.

18. The corrosion inhibition system of claim 16, wherein the substrate plated with the plating material, coated with the chemical conversion coating, and coated with the corrosion inhibition composition coating is dried for at least two hours at between 30 C. (86 F.) and 200 C. (392 F.).

19. A chemical conversion coating solution, comprising: a solvent; at least one corrosion inhibitive cation comprising at least one of zirconium, titanium, cerium, vanadium species, manganese, or niobium; at least one corrosion inhibitive anion comprising at least one of phosphate, molybdate, or silicate; at least one complexing agent; at least one oxidizer; and at least one organic polymer additive, wherein the at least one complexing agent is at least one of sulfuric acid, nitric acid, a fluorosilicic acid solution, Ethylenediaminetetraacetic acid (EDTA), tartaric acid, oxalic acid, phytic acid, citric acid, or glycine, wherein the at least one oxidizer is at least one of hydrogen peroxide (H.sub.2O.sub.2) or a permanganate compound, and wherein the at least one polymer additive is at least one of tannic acid, polyacrylic acid, polyvinyl alcohol, or polyvinylpyrrolidone.

20. The chemical conversion coating solution of claim 19, wherein the chemical conversion coating solution has a pH of between 3.5 and 12.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The subject matter of the present disclosure is particularly pointed out and distinctly claimed in the concluding portion of the specification. A more complete understanding of the present disclosure, however, may best be obtained by referring to the detailed description and claims when considered in connection with the drawing figures, wherein like numerals denote like elements.

[0026] FIG. 1 illustrates a chemical conversion coated plated material including a substrate coated with a plating material and a chemical conversion coating, in accordance with various embodiments.

[0027] FIG. 2 illustrates a chemical conversion coated plated material including a substrate coated with a plating material, a chemical conversion coating, and a corrosion inhibition composition, in accordance with various embodiments.

[0028] FIG. 3 illustrates a method of applying a chemical conversion coating to a substrate coated with plating material, in accordance with various embodiments.

[0029] FIG. 4 illustrates a method of applying a chemical conversion coating and a corrosion inhibition composition to a substrate coated with plating material, in accordance with various embodiments.

DETAILED DESCRIPTION

[0030] The following detailed description of various embodiments herein makes reference to the accompanying drawings, which show various embodiments by way of illustration. While these various embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, it should be understood that other embodiments may be realized and that changes may be made without departing from the scope of the disclosure. Thus, the detailed description herein is presented for purposes of illustration only and not of limitation. Furthermore, any reference to singular includes plural embodiments, and any reference to more than one component or step may include a singular embodiment or step. Also, any reference to attached, fixed, connected, or the like may include permanent, removable, temporary, partial, full or any other possible attachment option. Additionally, any reference to without contact (or similar phrases) may also include reduced contact or minimal contact. It should also be understood that unless specifically stated otherwise, references to a, an or the may include one or more than one and that reference to an item in the singular may also include the item in the plural. Further, all ranges may include upper and lower values and all ranges and ratio limits disclosed herein may be combined.

[0031] Corrosion inhibition systems used on metal and metal coated substrates are used in many industries. For example, aircraft landing gear often contains metal-coated substrates in landing gear components, which may be overcoated with a corrosion inhibition system. Metal and/or metal-coated substrates are also used in other contexts, such as in other vehicles such as automobiles, trains, and heavy equipment. In addition, metal coated substrates are found in construction contexts, such as used on building infrastructures.

[0032] In various embodiments, a corrosion inhibition system may comprise a plating material, a chemical conversion coating, and/or a corrosion inhibition composition, as described herein. As used herein, a substrate may include any metal and/or metal coated material. For example, a substrate may comprise iron, coated iron, steel, coated steel, stainless steel, coated stainless steel, nickel, coated nickel, aluminum, coated aluminum, bronze, coated bronze, copper beryllium, coated copper beryllium, zinc, and/or coated zinc, among others. In various embodiments, stainless steel may comprise a high strength stainless steel and may comprise a martensitic precipitation-hardening stainless steel. In various embodiments, a substrate may comprise a chromium-nickel-tungsten martensitic alloy (also known as Greck Ascoloy).

[0033] In various embodiments, a substrate may comprise a metal that is coated with a plating material. A plating material may be applied by electroplating, cold spraying or other suitable methods. Plating materials may comprise one or more metals, such as Nickel (Ni), Zinc (Zn), Cadmium (Cd), or Titanium (Ti), and combinations thereof. For example, in various embodiments, a substrate may comprise a coated steel or low alloy steel (e.g., 300M steel) comprising a ZnNi plating material. In various embodiments, a substrate may comprise a zinc alloy or zinc-nickel alloy. In various embodiments, a substrate may comprise a coated steel comprising a zinc plating material, and/or galvanized steel. In various embodiments, a substrate may comprise bare steel, and/or bare stainless steel. In various embodiments, a substrate may comprise aluminum-nickel-bronze alloys and/or copper alloys. In various embodiments, a substrate may comprise aluminum and aluminum alloys.

[0034] In various embodiments, a chemical conversion coating solution may be applied to the plating material on the substrate. The chemical conversion coating, which is the chemical conversion coating solution less the solvent (i.e., after drying), in conjunction with the plating material, may be configured to inhibit the corrosion of and protect the underlying substrate. In various embodiments, the chemical conversion coating solution may be a solution comprising a solvent (i.e., water) and a mixture of chemical conversion constituents. In various embodiments, the chemical conversion constituents may comprise a corrosion inhibitive cation species, and corrosion inhibitive anion species, and a complexing agent, where the corrosion inhibitive cation species and the corrosion inhibitive anion species are ions that exist in solution. In various embodiments, the inhibitive cation species may be any one or combination of a Zirconium species (Zr), a Titanium species (Ti), a Cerium species (Ce), a Vanadium species (V), a Manganese species (Mn), and/or a Niobium species (Nb), among others, in solution. In various embodiments, the corrosion inhibitive anion species may be any one or combination of a molybdate species, a silicate species, and/or a phosphate species in solution.

[0035] The corrosion inhibitive cation species and the corrosion inhibitive anion species may be provided by any soluble compound(s) to create a chemical conversion coating solution. In various embodiments, any of the corrosion inhibitive cation species may be provided by any soluble ionic compound, for example, comprising silicate, molybdate, phosphate, or any other suitable anion. The addition of the complexing agent to the chemical conversion coating solution allows the corrosion inhibitive cations and anions to exist in solution without reacting with one another to prevent, among other things, precipitation of one or more species. In various embodiments, the complexing agent may be sulfuric acid, nitric acid, a fluorosilicic acid solution, Ethylenediaminetetraacetic acid (EDTA), tartaric acid, oxalic acid, phytic acid, citric acid, or glycine, or any other suitable compound in combination with and oxidizer, such as hydrogen peroxide (H.sub.2O.sub.2) and/or a permanganate compound, such as potassium permanganate, to increase the oxidizing strength (i.e., the bonding of the chemical conversion coating solution with the plating material) of the chemical conversion coating solution. In various embodiments, the chemical conversion coating solution may comprise an application vehicle to aid the application of the chemical conversion coating to the plating material on a substrate.

[0036] In various embodiments, the corrosion inhibitive cation species and/or the corrosion inhibitive anion species may have a concentration in a range of 0.5 millimolar to 0.5 molar in the chemical conversion coating solution. In various embodiments, the corrosion inhibitive cation species and/or the corrosion inhibitive anion species may have a concentration in a range of 0.5 millimolar to 0.05 molar in the chemical conversion coating solution. In various embodiments, the corrosion inhibitive cation species and/or the corrosion inhibitive anion species may have a concentration in a range of 0.001 molar to 0.01 molar in the chemical conversion coating solution. That Is, any or all corrosion inhibitive cation species, and/or any or all corrosion inhibitive anion species, individually or in combination, may have the concentrations discussed above in the chemical conversion coating solution.

[0037] Various corrosion inhibitive cation species and corrosion inhibitive anion species have shown more of a potential to aid in corrosion protection of a substrate when existing in a solution and applied to the substrate. Accordingly, in addition to the various concentration ranges for constituents of the chemical conversion coating solution discussed herein, in various embodiments, the molybdate corrosion inhibitive anion may have a concentration in a range of 0.5 millimolar to 0.5 molar. In various embodiments, the molybdate compound may have a concentration in a range of 0.5 millimolar to 0.02 molar in the chemical conversion coating solution. In various embodiments, the molybdate compound may have a concentration in a range of 0.5 millimolar to 0.002 molar in the chemical conversion coating solution. In various embodiments, the molybdate compound may have a concentration in a range of 0.8 millimolar to 0.0015 molar in the chemical conversion coating solution. In various embodiments, the molybdate compound may have a concentration of about 0.001 molar in the chemical conversion coating solution. The term about as used in this context only means plus or minus 0.5 millimolar. In various embodiments, the silicate corrosion inhibitive anion and/or the complexing agent may have a concentration in a range of 0.5 millimolar to 0.5 molar. In various embodiments, the silicate corrosion inhibitive anion may have a concentration in a range of 0.005 molar to 0.02 molar in the chemical conversion coating solution. In various embodiments, the silicate compound anion may have a concentration in a range of 0.008 molar to 0.015 molar in the chemical conversion coating solution. In various embodiments, the silicate compound anion may have a concentration of about 0.010 molar in the chemical conversion coating solution. The term about as used in this context only means plus or minus 0.002 molar.

[0038] In various embodiments, the complexing agent may have a concentration that matches the concentration of the corrosion inhibitive cation species and/or the corrosion inhibitive anion species. Accordingly, the complexing agent may have a concentration in a range of 0.05 millimolar to 0.020 molar in the chemical conversion coating solution. In various embodiments, the complexing agent may have a concentration in a range of 0.1 millimolar to 0.01 molar in the chemical conversion coating solution. In various embodiments, the complexing agent may have a concentration in a range of 0.5 millimolar to 0.02 molar in the chemical conversion coating solution. In various embodiments, the organic binder may have a mass concentration of 0.05 to 0.7 millimolar in the chemical conversion coating solution. In various embodiments, the organic binder may have a mass concentration of 0.1 to 0.5 millimolar in the chemical conversion coating solution.

[0039] In various embodiments, the chemical conversion coating solution may comprise a complexing agent, such as sulfuric acid, nitric acid, a fluorosilicic acid solution, Ethylenediaminetetraacetic acid (EDTA), tartaric acid, oxalic acid, phytic acid, citric acid, or glycine, or any other suitable acid or base to regulate the pH of the chemical conversion coating solution. In various embodiments, the chemical conversion coating solution may have a pH between 3.5 and 12. In various embodiments, the chemical conversion coating solution may have a pH between 5 and 10.5. In various embodiments, the chemical conversion coating solution may have a pH between 6.5 and 9. The corrosion inhibitive cation species and corrosion inhibitive anion species surprisingly show a synergistic effect at inhibiting corrosion on a substrate in response to co-existing within a solution.

[0040] In various embodiments, the chemical conversion coating solution may be applied via dipping in a bath in order to distribute or apply the material coating of a substrate and allowed to dry to form the chemical conversion coating. For example, a chemical conversion coating solution may be applied by immersion of the substrate into the chemical conversion coating solution. In various embodiments, the chemical conversion coating solution temperature may be between 30 C. (86 F.) and 100 C. (212 F.). In various embodiments, the chemical conversion coating solution temperature may be between 50 C. (122 F.) and 95 C. (203 F.). In various embodiments, the chemical conversion coating solution temperature may be between 75 C. (167 F.) and 95 C. (203 F.). In various embodiments, the chemical conversion coating solution may be applied to the plating material on the substrate and allowed to air dry at about 20 C. (about 68 F.). When used in this context only, the term about means plus or minus 5 C. (9 F.). In various embodiments, the chemical conversion coating solution may be rinsed with water prior to air drying.

[0041] Referring now to FIG. 1, in accordance with various embodiments, a chemical conversion coated plated material 100 including a substrate 102 plated with a plating material 104 and a chemical conversion coating 106 is illustrated. In various embodiments, the plating material 104 may comprise Zn and/or Ni. In various embodiments, the chemical conversion coating 106 is disposed adjacent to the plating material 104, such that the plating material 104 is between the chemical conversion coating 106 and the substrate 102. In various embodiments, the chemical conversion coating 106 may include at least a corrosion inhibitive anion and a corrosion inhibitive cation, among other agents, as described herein. In various embodiments, the corrosion inhibitive anion may be any one or combination of a molybdate, a silicate, and/or a phosphate. In various embodiments, the corrosion inhibitive cation may be any one or combination of a Zirconium species (Zr), a Titanium species (Ti), a Cerium species (Ce), a Vanadium species (V), a Manganese species (Mn), and/or a niobium species (Nb), among others.

[0042] In various embodiments, in order to coat the substrate 102 plated with the plating material 104 with the chemical conversion coating 106, the plating material 104 may first be degreased. In various embodiments, the plating material 104 may be degreased using a degreaser, such as acetone or methyl acetate or other solvent and/or surfactant, among others. In various embodiments, the plating material 104 may be rinsed to remove any remaining degreaser. In various embodiments, the plating material 104 may then be activated using an activator, such as nitric acid or alkaline immersion cleaner, among others. In various embodiments, the plating material 104 may be rinsed to remove any remaining activator. In various embodiments, the substrate 102 plated with the plating material 104, which has been degreased and activated, may then be dipped into a bath of a conversion coating solution. As stated previously, the chemical conversion solution may include at least a corrosion inhibitive anion and a corrosion inhibitive cation, among other agents, as described herein. In various embodiments, the corrosion inhibitive anion may be any one or combination of a molybdate, a silicate, and/or a phosphate. In various embodiments, the corrosion inhibitive cation may be any one or combination of a Zirconium species (Zr), a Titanium species (Ti), a Cerium species (Ce), a Vanadium species (V), a Manganese species (Mn), and/or a niobium species (Nb), among others, to form the chemical conversion coating 106 on the plating material 104. In various embodiments, the chemical conversion coating solution may have a required pH to specify the acidity or basicity of the chemical conversion coating solution. In various embodiments, the pH may be between 3.5 and 12. In various embodiments, the pH may be between 5 and 10.5. In various embodiments, the pH may be between 6.5 and 9.

[0043] In various embodiments, during the forming of the chemical conversion coating 106, the chemical conversion coating solution may be maintained at a temperature between 5 C. (41 F.) and 90 C. (194 F.). In various embodiments, during the forming of the chemical conversion coating 106, the chemical conversion coating solution may be maintained at a temperature between 20 C. (68 F.) and 70 C. (158 F.). In various embodiments, during the forming of the chemical conversion coating 106, the chemical conversion coating solution may be maintained at a temperature between 40 C. (104 F.) and 60 C. (140 F.). In various embodiments, a time in which the substrate 102 plated with the plating material 104 is immersed in the chemical conversion coating solution may be between 2 minutes to 20 minutes. In various embodiments, a time in which the substrate 102 plated with the plating material 104 is in the chemical conversion coating solution may be between 2 minutes to 10 minutes. In various embodiments, a time in which the substrate 102 plated with the plating material 104 is immersed in the chemical conversion coating solution may be between 2 minutes to 5 minutes.

[0044] In various embodiments, the substrate 102 plated with the plating material 104 and coated with the chemical conversion coating 106 may then be rinsed to remove any remaining conversion coating solution and dried. In various embodiments, the substrate 102 plated with the plating material 104 and coated with the chemical conversion coating 106 may be dried at between 30 C. (86 F.) and 200 C. (392 F.). In various embodiments, the substrate 102 plated with the plating material 104 and coated with the chemical conversion coating 106 may be dried at between 40 C. (104 F.) and 190 C. (374 F.). In various embodiments, the substrate 102 plated with the plating material 104 and coated with the chemical conversion coating 106 may be dried at 180 C. (356 F.). In various embodiments, the substrate 102 plated with the plating material 104 and coated with the chemical conversion coating 106 may be dried for between 2 hours and 4 hours. In various embodiments, the substrate 102 plated with the plating material 104 and coated with the chemical conversion coating 106 may be dried for between 2 hours and 3 hours. In various embodiments, the substrate 102 plated with the plating material 104 and coated with the chemical conversion coating 106 may be dried for 2+ hours.

[0045] Referring now to FIG. 2, in accordance with various embodiments, a chemical conversion coated plated material 200 including a substrate 202 coated with plating material 204, a chemical conversion coating 206, and a corrosion inhibition composition 208 is illustrated. In various embodiments, the plating material 204 may comprise Zn and/or Ni. In various embodiments, chemical conversion coating 206 is disposed adjacent to plating material 204, such that the plating material 204 is between the chemical conversion coating 206 and the substrate 202. In various embodiments, the corrosion inhibition composition 208 is disposed adjacent to the chemical conversion coating 206, such that the chemical conversion coating 206 is between the plating material 204 and the corrosion inhibition composition 208.

[0046] In various embodiments, the chemical conversion coating 206 may include at least a corrosion inhibitive anion and a corrosion inhibitive cation, among other agents, as described herein. In various embodiments, the corrosion inhibitive anion may be any one or combination of a molybdate, a silicate, and/or a phosphate. In various embodiments, the corrosion inhibitive cation may be any one or combination of a Zirconium species (Zr), a Titanium species (Ti), a Cerium species (Ce), a Vanadium species (V), a Manganese species (Mn), and/or a niobium species (Nb), among others.

[0047] In various embodiments, corrosion inhibition composition 208 may include any one or combination of a molybdate, a silicate, and/or a phosphate. In various embodiments, the corrosion inhibition composition 208 may have a required pH to specify the acidity or basicity of the corrosion inhibition composition 208, which requires a specific molar ratio of Mo/Si/P, such as (1:6:3).

[0048] In various embodiments, in order to coat the substrate 202 plated with the plating material 204 with the chemical conversion coating 206, the plating material 204 may first be degreased. In various embodiments, the plating material 204 may be degreased using a degreaser, such as acetone or methyl acetate, among others. In various embodiments, the plating material 204 may be rinsed to remove any remaining degreaser. In various embodiments, the plating material 204 may then be activated using an activator, such as nitric acid or alkaline immersion cleaner, among others. In various embodiments, the plating material 204 may be rinsed to remove any remaining activator. In various embodiments, the substrate 202 plated with the plating material 204, which has been degreased and activated, may then be dipped into a bath of a conversion coating solution. As stated previously, the chemical conversion solution may include at least a corrosion inhibitive anion and a corrosion inhibitive cation, among other agents, as described herein. In various embodiments, the corrosion inhibitive anion may be any one or combination of a molybdate, a silicate, and/or a phosphate. In various embodiments, the corrosion inhibitive cation may be any one or combination of a Zirconium species (Zr), a Titanium species (Ti), a Cerium species (Ce), a Vanadium species (V), a Manganese species (Mn), and/or a niobium species (Nb), among others, to form the chemical conversion coating 206 on the plating material 204. In various embodiments, the chemical conversion coating solution may have a required pH to specify the acidity or basicity of the chemical conversion coating solution. In various embodiments, the pH may be between 3.5 and 12. In various embodiments, the pH may be between 5 and 10.5. In various embodiments, the pH may be between 6.5 and 9.

[0049] In various embodiments, during the forming of the chemical conversion coating 206, the chemical conversion coating solution may be maintained at a temperature between 5 C. (41 F.) and 90 C. (194 F.). In various embodiments, during the forming of the chemical conversion coating solution, the chemical conversion coating solution may be maintained at a temperature between 20 C. (68 F.) and 70 C. (158 F.). In various embodiments, during the forming of the chemical conversion coating solution, the chemical conversion coating solution may be maintained at a temperature between 40 C. (104 F.) and 60 C. (140 F.). In various embodiments, a time in which the substrate 202 plated with the plating material 204 is immersed in the chemical conversion coating solution may be between 2 minutes to 20 minutes. In various embodiments, a time in which the substrate 202 plated with the plating material 204 is immersed in the chemical conversion coating solution may be between 2 minutes to 10 minutes. In various embodiments, a time in which the substrate 202 plated with the plating material 204 is immersed in the chemical conversion coating solution may be between 2 minutes to 5 minutes.

[0050] In various embodiments, the substrate 202 plated with the plating material 204 and coated with the chemical conversion coating 206 may then be rinsed to remove any remaining conversion coating solution and dried. In various embodiments, the substrate 202 plated with the plating material 204 and coated with the chemical conversion coating 206, may then be dipped into a bath of a corrosion inhibition composition solution. As stated previously, the corrosion inhibition composition solution may include any one or combination of a molybdate, a silicate, and/or a phosphate. In various embodiments, the corrosion inhibition composition solution may have a required pH to specify the acidity or basicity of the corrosion inhibition composition solution, which requires a specific molar ratio of Mo/Si/P, such as (1:6:3). In various embodiments, the pH may be between 6 and 14. In various embodiments, the pH may be between 7 and 13. In various embodiments, the pH may be between 8 and 12. In various embodiments, the corrosion inhibition composition solution may further comprise an organic polymer additive such as tannic acid, polyacrylic acid, polyvinyl alcohol, or polyvinylpyrrolidone, among others.

[0051] In various embodiments, during the forming of the corrosion inhibition composition 208, the corrosion inhibition composition solution may be maintained at a temperature between 10 C. (50 F.) and 115 C. (239 F.). In various embodiments, during the forming of the corrosion inhibition composition 208, the corrosion inhibition composition solution may be maintained at a temperature between 20 C. (68 F.) and 105 C. (221 F.). In various embodiments, during the forming of the corrosion inhibition composition 208, the corrosion inhibition composition solution may be maintained at a temperature between 30 C. (86 F.) and 95 C. (203 F.). In various embodiments, a time in which the substrate 202 plated with the plating material 204 and coated with the chemical conversion coating 206 is immersed in the corrosion inhibition composition solution may be between 3 minutes to 12 minutes. In various embodiments, a time in which the substrate 202 plated with the plating material 204 and coated with the chemical conversion coating 206 is immersed in the corrosion inhibition composition solution may be between 4 minutes to 11 minutes. In various embodiments, a time in which the substrate 202 plated with the plating material 204 and coated with the chemical conversion coating 206 is immersed in the corrosion inhibition composition solution may be between 5 minutes to 10 minutes.

[0052] In various embodiments, the substrate 202 plated with the plating material 204 and coated with the chemical conversion coating 206 and the corrosion inhibition composition 208 may then be rinsed to remove any remining corrosion inhibition composition and dried. In various embodiments, the substrate 202 plated with the plating material 204 and coated with the chemical conversion coating 206 and the corrosion inhibition composition 208 may be dried at between 30 C. (86 F.) and 200 C. (392 F.). In various embodiments, the substrate 202 plated with the plating material 204 and coated with the chemical conversion coating 206 and the corrosion inhibition composition 208 may be dried at between 40 C. (104 F.) and 190 C. (374 F.). In various embodiments, the substrate 202 plated with the plating material 204 and coated with the chemical conversion coating 206 and the corrosion inhibition composition 208 may be dried at 180 C. (356 F.). In various embodiments, the substrate 202 plated with the plating material 204 and coated with the chemical conversion coating 206 and the corrosion inhibition composition 208 may be dried for between 2 hours and 4 hours. In various embodiments, the substrate 202 plated with the plating material 204 and coated with the chemical conversion coating 206 and the corrosion inhibition composition 208 may be dried for between 2 hours and 3 hours. In various embodiments, the substrate 202 plated with the plating material 204 and coated with the chemical conversion coating 206 and the corrosion inhibition composition 208 may be dried for 2+ hours.

[0053] Referring now to FIG. 3, in accordance with various embodiments, a method 300 for applying a chemical conversion coating to a substrate coated with plating material is illustrated. In various embodiments, at block 302 a chemical conversion coating solution is formed. In various embodiments, the chemical conversion coating solution may include at least a corrosion inhibitive anion and a corrosion inhibitive cation, among other agents, as described herein. In various embodiments, the corrosion inhibitive anion may be any one or combination of a molybdate, a silicate, and/or a phosphate. In various embodiments, the corrosion inhibitive cation may be any one or combination of a Zirconium species (Zr), a Titanium species (Ti), a Cerium species (Ce), a Vanadium species (V), a Manganese species (Mn), and/or a niobium species (Nb), among others.

[0054] In various embodiments, at block 304, the in order to coat the substrate plated with the plating material with the chemical conversion coating solution, the plating material is degreased. In various embodiments, the plating material may be degreased using a degreaser, such as acetone or methyl acetate, among others. In various embodiments, at block 306, the plating material is rinsed to remove any remaining degreaser. In various embodiments, at block 308, the plating material is then activated using an activator, such as nitric acid or alkaline immersion cleaner, among others. In various embodiments, at block 310, the plating material is rinsed to remove any remaining activator. In various embodiments, at block 312 the substrate plated with the plating material, which has been degreased and activated, is dipped into a bath of the formed conversion coating solution. As stated previously, the chemical conversion solution may include at least a corrosion inhibitive anion and a corrosion inhibitive cation, among other agents, as described herein. In various embodiments, at block 314, the plated substrate plated with the plating material and coated with the chemical conversion coating is rinsed to remove any remaining conversion coating solution and dried.

[0055] Referring now to FIG. 4, in accordance with various embodiments, a method 400 for applying a chemical conversion coating and a corrosion inhibition composition to a substrate coated with plating material is illustrated. In various embodiments, at block 402 a chemical conversion coating solution is formed. In various embodiments, the chemical conversion coating solution may include at least a corrosion inhibitive anion and a corrosion inhibitive cation, among other agents, as described herein. In various embodiments, the corrosion inhibitive anion may be any one or combination of a molybdate, a silicate, and/or a phosphate. In various embodiments, the corrosion inhibitive cation may be any one or combination of a Zirconium species (Zr), a Titanium species (Ti), a Cerium species (Ce), a Vanadium species (V), a Manganese species (Mn), and/or a niobium species (Nb), among others. In various embodiments, at block 404, a corrosion inhibition composition solution is formed. In various embodiments, the corrosion inhibition composition solution may include any one or combination of a molybdate, a silicate, and/or a phosphate.

[0056] In various embodiments, at block 406, the in order to coat the substrate plated with the plating material with the chemical conversion coating solution, the plating material is degreased. In various embodiments, the plating material may be degreased using a degreaser, such as acetone or methyl acetate, among others. In various embodiments, at block 408, the plating material is rinsed to remove any remaining degreaser. In various embodiments, at block 410, the plating material is then activated using an activator, such as nitric acid or alkaline immersion cleaner, among others. In various embodiments, at block 412, the plating material is rinsed to remove any remaining activator. In various embodiments, at block 414 the substrate plated with the plating material, which has been degreased and activated, is dipped into a bath of the formed conversion coating solution. As stated previously, the chemical conversion solution may include at least a corrosion inhibitive anion and a corrosion inhibitive cation, among other agents, as described herein. In various embodiments, at block 416, the plated substrate plated with the plating material and coated with the chemical conversion coating is rinsed to remove any remaining conversion coating solution. In various embodiments, at block 418, the substrate plated with the plating material and coated with the chemical conversion coating is then dipped into a bath of the corrosion inhibition composition solution. In various embodiments, at block 420, the substrate plated with the plating material and coated with the chemical conversion coating and the corrosion inhibition composition may then be rinsed to remove any remaining corrosion inhibition composition solution and dried.

[0057] Benefits, other advantages, and solutions to problems have been described herein with regard to specific embodiments. Furthermore, the connecting lines shown in the various figures contained herein are intended to represent exemplary functional relationships and/or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical system. However, the benefits, advantages, solutions to problems, and any elements that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements of the disclosure. The scope of the disclosure is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean one and only one unless explicitly so stated, but rather one or more. Moreover, where a phrase similar to at least one of A, B, or C is used in the claims, it is intended that the phrase be interpreted to mean that A alone may be present in an embodiment, B alone may be present in an embodiment, C alone may be present in an embodiment, or that any combination of the elements A, B and C may be present in a single embodiment; for example, A and B, A and C, B and C, or A and B and C. Different cross-hatching is used throughout the figures to denote different parts but not necessarily to denote the same or different materials.

[0058] Systems, methods and apparatus are provided herein. In the detailed description herein, references to one embodiment, an embodiment, various embodiments, etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiments.

[0059] Numbers, percentages, or other values stated herein are intended to include that value, and also other values that are about or approximately equal to the stated value, as would be appreciated by one of ordinary skill in the art encompassed by various embodiments of the present disclosure. A stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result. The stated values include at least the variation to be expected in a suitable industrial process, and may include values that are within 10%, within 5%, within 1%, within 0.1%, or within 0.01% of a stated value. Additionally, the terms substantially, about or approximately as used herein represent an amount close to the stated amount that still performs a desired function or achieves a desired result. For example, the term substantially, about or approximately may refer to an amount that is within 10% of, within 5% of, within 1% of, within 0.1% of, and within 0.01% of a stated amount or value.

[0060] Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is intended to invoke 35 U.S.C. 112(f) unless the element is expressly recited using the phrase means for. As used herein, the terms comprises, comprising, or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.

[0061] Finally, it should be understood that any of the above-described concepts can be used alone or in combination with any or all of the other above-described concepts. Although various embodiments have been disclosed and described, one of ordinary skill in this art would recognize that certain modifications would come within the scope of this disclosure. Accordingly, the description is not intended to be exhaustive or to limit the principles described or illustrated herein to any precise form. Many modifications and variations are possible in light of the above teaching.