Metallic articles having dual layers of electroless metal coatings incorporating particulate matter

Claim 2

A metallized article produced by the steps comprising: (1) contacting said article with an electroless plating bath further comprising insoluble suspended particulate matter to provide a composite layer comprising a member selected from the group consisting of a metal, a metal alloy, and mixtures thereof, and the insoluble particulate matter, (2) contacting said treated article with an electroless plating bath to provide a layer comprising a member selected from the group consisting of a metal, a metal alloy, and mixtures thereof, said layer being substantially free of particulate matter substantially covering the particulate matter exposed from step 1, and subsequently (3) removing a portion of the electrolessly deposited layer deposited in step 2 thereby providing a smoother surface finish in comparison to the surface finish after step 1, however retaining a sufficient amount of electroless metal from step 2 to substantially cover the particulate matter exposed from step 1.

Claim 3

The article according to claim 1 wherein said electroless plating bath used in step 1 is nickel phosphorous.

Claim 4

The article according to claim 1 wherein said particulate matter is wear-resistant particles having particle size in the range of 0.5 to 70 microns.

Claim 5

The article according to claim 1 wherein said particulate matter is diamonds.

Claim 6

The article according to claim 1 wherein said particles are polycrystalline diamond.

Claim 7

The article according to claim 1 wherein said metallic article is a friction texturing disc.

Claim 8

The article according to claim 1 wherein said metallic article is aluminum or aluminum alloy.

Claim 9

The article according to claim 1 produced by the further step of heat treatment.

Claim 10

The article according to claim 1 wherein said particulate matter is polycrystalline diamond and wherein said diamond with said composite coated layer constitutes in a range of 20 to 30 volume percent.

Claim 11

The article according to claim 1 wherein said article is steel.

Claim 12

The article according to claim 1 wherein said metallic article is a rotor.

Claim 13

The article according to claim 1 wherein said article is a roll used in open end spinning.

Claim 14

The article according to claim 1 produced by the further step of heat treatment thereby resulting in the electroless nickel matrix having a hardness of approximately 70 Rockwell units.

Claim 15

The article according to claim 1 wherein said particulate matter is wear-resistant particles having a hardness greater than said matrix.

Claim 16

The article according to claim 1 wherein said particulate matter is polycrystalline wear-resistant particles.

Claim 17

The article according to claim 1 wherein said particulate matter is 6 micron particle size.

Claim 18

The article according to claim 1 wherein said electroless plating bath used in step 1 provides with a coating comprising of approximately 88 to 93 percent nickel and approximately 7 to 11 percent phosphorous in the coating devoid of the particulate matter.

Claim 19

A process for the metallization of a substrate comprising the steps: (1) contacting said substrate with an electroless plating bath further comprising insoluble suspended particulate matter to provide a composite layer comprising a member selected from the group consisting of a metal, a metal alloy, and mixtures thereof, and the insoluble particulate matter, (2) contacting the treated substrate with an electroless plating bath to provide a layer comprising a member selected from the group consisting of a metal, a metal alloy, and mixtures thereof, said layer being substantially free of particulate matter substantially covering the particulate matter exposed from step 1, and subsequently (3) removing a portion of the electrolessly deposited layer deposited in step 2 thereby providing a smoother surface finish in comparison to the surface finish after step 1, however retaining a sufficient amount of electroless metal from step 2 to substantially cover the particulate matter exposed from step 1.

Claim 20

A process for the metallization of a substrate comprising the steps: (1) contacting said substrate with an electroless plating bath further comprising insoluble suspended particulate matter to provide a composite layer comprising a member selected from the group consisting of a metal, a metal alloy, and mixtures thereof, and the insoluble particulate matter, (2) contacting the treated substrate with an electroless plating bath to provide a layer comprising a member selected from the group consisting of a metal, a metal alloy, and mixtures thereof, said layer being substantially free of particulate matter substantially covering the particulate matter exposed from step 1, and subsequently (3) removing a portion of the electrolessly deposited layer deposited in step 2 thereby providing a smoother surface finish in comparison to the surface finish after step 1, however retaining a sufficient amount of electroless metal from step 2 to substantially cover the particulate matter exposed from step 1.

Claim 21

The process according to claim 18 wherein said substrate is aluminum.

Claim 22

The process according to claim 18 wherein said substrate is an alloy of aluminum.

Claim 23

The process according to claim 18 wherein said electroless plating bath used in step 1 is nickel phosphorous.

Claim 24

The process according to claim 18 wherein said electroless plating bath used in step 2 is nickel phosphorous.

Claim 25

The process according to claim 18 wherein said particulate matter is a wear-resistant particle.

Claim 26

The process according to claim 18 wherein said particulate matter is diamond.

Claim 27

The process to claim 18 wherein said particulate matter is diamond of a polycrystalline type.

Claim 28

The process according to claim 18 wherein said substrate is a friction texturing disc as used in texile machinery.

Claim 29

The process according to claim 18 wherein said substrate is aluminum or aluminum alloy and wherein said part is a rotor as used in textile machinery.

Claim 30

The process according to claim 18 wherein said substrate after metallization is further smoothed to a surface roughness in the range of 10 to 20 AA units.

Claim 31

The metallized article according to claim 1 further produced by a surface smoothing which results in a surface roughness in the range of 10 to 20 AA units.

Claim 32

The process according to claim 18 wherein the metallized substrate is further smoothed.

Claim 33

The process according to claim 30 wherein said metallized substrate is a textile machinery part.

Claim 34

The process according to claim 31 wherein said textile machinery part is selected from the group consisting of discs, rotors, and rolls.

Claim 35

The process according to claim 30 wherein said substrate is aluminum or aluminum alloy.

Claim 36

The process according to claim 30 wherein said substrate is steel.

Claim 37

The process according to claim 30 wherein said metallized substrate is comprised of nickel and phosphorous.

Claim 38

The process according to claim 30 wherein said metallized substrate consists of a metallic matrix having a hardness of approximately 70 Rockwell units.

Claim 39

The process according to claim 30 wherein said metallized substrate comprises particulate matter selected from the group consisting of diamond, silicon carbide, and aluminum oxide.

Claim 40

The metallized article according to claim 1 having an increased surface roughness after step 2 in comparison to the surface roughness at the conclusion of step 1.

Claim 41

The process according to claim 18 whereby the metal deposition of step 2 increases the surface roughness in comparison to the surface roughness at the conclusion of step 1.