SYSTEM AND METHOD FOR ELECTROFORMED COATING ON A COMPONENT

Description

TECHNICAL FIELD

The present subject matter relates generally to an electroforming method and system, and more specifically to methods of electroforming coatings on components for gas turbine engines and turbine engine components formed therefrom.

BACKGROUND

An electroforming process can create, generate, or otherwise form a metallic layer of a component. In one example, a mold or base for the component can be submerged in an electrolytic liquid and electrically charged. The electric charge of the mold can attract an oppositely-charged electroforming material through the electrolytic solution. The electrical attraction of the electroforming material to the mold deposits the electroforming material onto exposed surfaces of the mold, creating a layer of the electroforming material on the mold.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present disclosure, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:

FIG. 1 is a schematic perspective view of an electrodeposition system for forming a component, in accordance with various aspects described herein.

FIG. 2 is a schematic cross-sectional view of an electroformed component formed in the electrodeposition system of FIG. 1, in accordance with various aspects described herein.

FIG. 3 is a flow chart describing a method of electroforming a coating for a component, in accordance with various aspects described herein.

DETAILED DESCRIPTION

Aspects of the present disclosure are directed to system and methods for electroforming a component, and more particularly, to electroforming a coating onto a component, such as a component of a turbine engine. It will be understood that the disclosure can have general applicability in a variety of applications, including that the electroformed component can be utilized in any suitable mobile and non-mobile industrial, commercial, and residential applications.

Electrodeposition such as electroforming is a process where coated metal parts are formed through electrolytic reduction of metal ions on the surface of a mandrel or cathode to form the coated component. In a typical electroforming process, a mandrel (cathode) and an anode are immersed in an electrolyte solution. A metal layer forming a part thickness deposited on the mandrel surface over time as current is passed between the anode and cathode. Once the intended thickness is reached, the mandrel can be removed from the bath tank. Electrodeposition is used to manufacture products across a range of industries including healthcare, electronics, and aerospace. Electrodeposition or electroforming manufacturing processes offers several advantages, including that such processes are efficient, precise, scalable, and low-cost.

As used herein, “electrodeposition” will include any process for building, forming, growing, or otherwise creating a metal layer over another substrate or base. Non-limiting examples of electrodeposition can include electroforming, electroless forming, electroplating, or a combination thereof. While an electroforming process is generally described herein, it will be understood that aspects of the disclosure are applicable to any and all electrodeposition processes.

All directional references (e.g., interior, exterior, etc.) are only used for identification purposes to aid the reader's understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of the disclosure. Connection references (e.g., coupled, connected) are to be construed broadly and can include intermediate members between a collection of elements and relative movement between elements unless otherwise indicated. As such, connection references do not necessarily infer that two elements are directly connected and in fixed relation to one another. In addition, as used herein “a set” can include any number of the respectively described elements, including only one element. The exemplary drawings are for purposes of illustration only and the dimensions, positions, order, and relative sizes reflected in the drawings attached hereto can vary.

Turbine engine components, such as fan blades, airfoils, shrouds, or other elements can be made of Aluminum or Aluminum composites. Aluminum is subject to corrosion, and therefore limits lifetime of the turbine engine components, or requires maintenance to inspect or repair corroded components. Conventional solutions for the corrosion of Aluminum include applying organic coatings due their lightweight properties. However, foreign debris, such as dust and grit, erode the organic coatings to expose the underlying Aluminum, which then becomes susceptible to corrosion, and necessitates reapplication of the organic coatings as well as inspection maintenance to identify which turbine engine components require reapplication. This process increases cost, maintenance time, and engine down time. Therefore, a material with a high hardness that mitigates corrosion while being resistant to erosion is needed.

FIG. 1 is a schematic illustration of an electroforming system 24 including an electrodeposition tank 10. The electrodeposition tank 10 can contain an electrolytic solution 12 comprising metal ions. At least one electrode can be provided in the electrodeposition tank 10 and can include an anode 14 and a cathode 16. The anode 14 can be a soluble or non-soluble anode, in non-limiting examples. A component 30 to be electroformed can form the cathode 16, for example, and can be submerged within the electrolytic solution 12. In embodiments described herein, the cathode 16 may be a turbine engine component, such as a turbine fan blade, an airfoil, a blade, a vane, a shroud, or a combustor liner in non-limiting examples. For example, and without limitation, the turbine engine component may be a fan blade for a turbine engine, such as a fan blade formed from or comprising aluminum.

A power source 18, which can include a controller or controller module, can electrically couple to the anode 14 and the cathode 16 by electrical conduits 20 to form a circuit via the conductive electrolytic solution 12. Optionally, a switch 22 or sub-controller can be included along the electrical conduits 20 between the power source 18, anode 14, and cathode 16. During operation, a current can be supplied from the anode 14 to the cathode 16 through the electrolytic solution 12 to the cathode 16. Supply of the current can cause metal ions from the electrolytic solution 12 to deposit onto the cathode 16, forming a coating 32 on the component 30 at the cathode 16.

In one example, the electrolytic solution 12 can include greater than or equal to 40% and less than or equal to 70% nickel sulfamate (H₄N₂NiO₆S₂), while greater ranges are contemplated, such as greater than or equal to 30% and less than or equal to 80% nickel sulfamate. The electrolytic solution 12 can further include greater than or equal to 1% and less than or equal to 15% cobalt sulfamate (CoH₄N₂O₆S₂), while a greater range is contemplated, such as greater than or equal to 1% and less than or equal to 20% cobalt sulfamate. The electrolytic solution 12 can further include greater than or equal to 20% and less than or equal to 50% deionized water, where percentages are by total volume of the electrolytic solution 12. A greater range for the deionized water is further contemplated, such as including greater than or equal to 10% deionized water and less than or equal to 60% deionized water. Additionally, the electrolytic solution 12 can further include greater than or equal to 0.1 milliliters (ml) and less than or equal to 10 milliliters (ml) of a paraffin additive, or a wetting agent, such as a wetting agent for sulfamate nickel or sulfamate cobalt solutions, which can reduce surface tension of the solution in order to promote mixing of the solution by reducing cohesion between molecules of the electrolytic solution 12. A greater range for the paraffin or wetting agent can be greater than or equal to 0.1 milliliters and less than or equal to 20 milliliters. In one non-limiting example, Barrett Snap-L can be utilized. Additionally, the electrolytic solution 12 can further include greater than or equal to 0.01 grams per liter and less than or equal to 50 grams per liter of Boric Acid (H₃BO₃), greater than or equal to 0.01 grams per liter and less than or equal to 10 grams per liter of Saccharin (benzoic sulfimide, C₇H₅NO₃S), and greater than or equal to 0.01 grams per liter and less than or equal to 1.0 grams per liter of phosphorus acid (H₃PO₃), where liters represent the total volume of the electrolytic solution 12. Greater ranges for these values can include greater than or equal to 0.01 grams per liter and less than or equal to 100 grams per liter of Boric Acid, greater than or equal to 0.01 grams per liter and less than or equal to 20 grams of Saccharin, greater than or equal to 0.01 grams per liter or less than or equal to 2.0 grams per liter of phosphorus acid, in non-limiting examples.

Further still, the voltage applied to the electrolytic solution 12 can be greater than or equal to 0.5 volts and less than or equal to 5.0 volts, while a greater range can include greater than or equal to 0.1 volts and less than or equal to 10.0 volts. The bath pH can be greater than or equal to 2 and less than or equal to 6, while a greater range can be greater than or equal to 1 and less than or equal to 7. The temperature for the electrolytic solution 12 bath can be greater than or equal to 35° C. and less than or equal to 65° C., while a greater range can be greater than or equal to 20° C. and less than or equal to 100° C. Controlling the voltage, pH, and temperature for the electrolytic solution 12 affects properties of the electrodeposited materials, such as hardness, in a non-limiting example.

During operation, a current can be supplied from the power source 18, and pass from the anode 14 to the cathode 16 to deposit a coating 32 at the cathode 16. Supply of the current in the electrolytic solution 12 can cause ions (i.e., nickel ions, cobalt ions, and phosphorous ions from the electrolytic solution 12) to move toward and accumulate onto the cathode 16 to form the coating 32. In this manner, the coating 32 can be formed over any surface of the cathode 16.

Aspects of the present disclosure provide for an electrodeposition process that can be used to at least partially cover the cathode 16 with a coating 32 that is amorphous in order to form the component 30. Such a component 30 can be a turbine engine component including but not limited to an airfoil, a fan blade, a turbine blade or vane, a compressor blade or vane, a disk, a combustor liner, shroud, or element or other exposed surface within a turbine engine. The cathode 16 can be used to form a component 30, such as an aluminum component, such as an airfoil, or can be a composite component, such as a composite fan blade at least partially made from Aluminum and utilized within a turbine engine, in non-limiting examples. Additional alternative non-limiting examples for the component 30 can include composite components, composite materials, woven structures, or preforms. Such an amorphous coating can provide enhanced hardness, as well as enhanced corrosion and erosion resistance under high-cycle operation or fatigue.

Referring now to FIG. 2, a section view of the component 30 includes the coating 32 electroformed onto an exterior surface 34 of the cathode 16. Additionally, in embodiments, a non-conductive coating 38 is provided on the cathode 16, spaced from the exterior surface 34, preventing electrodeposition along the non-conductive areas of the cathode 16 having the non-conductive coating 38. While embodiments are described herein as comprising a non-conductive coating 38, it should be understood that the non-conductive coating is optional and that, in alternative embodiments, the process of electrodepositing the coating on the cathode does not utilize a non-conductive coating on the cathode.

While the coating 32 is shown as only provided on one exterior surface 34 as shown in FIG. 2, it should be appreciated that the coating 32, or the non-conductive coating 38, can be provided on any portion of the cathode 16, such as along the entirety of the exterior surface 34 of the cathode 16, or a portion thereof, or can be discretely applied to discrete areas of the cathode 16. Additional contemplated portions include interior surface areas (not shown), such as interior passages or cavities, which can be in contact with the electrolytic solution 12 when within the electrodeposition tank 10 of FIG. 1.

The coating 32 can include a thickness 36. In one non-limiting example, the thickness 36 can be greater than or equal to 1 micrometers and less than or equal to 75 micrometers. For example, the thickness 6 of the coating can be greater than or equal to 1 micrometer and less than or equal to 100 micrometers. While coatings having a thickness of greater than or equal to 1 micrometer and less than or equal to 75 micrometers are specifically described, it should be understood that larger thicknesses are contemplated and possible.

The coating 32 can be a nickel-cobalt phosphate (NiCoP), and can be an amorphous coating. The term amorphous, as used herein, can mean that the coating 32 does not have any discernible grain boundaries, or having grains that are sized to have no discernible grain boundaries or have no discernible long-range order. In one non-limiting example, no discernible grains or grains with no discernible long-range order can mean that the grains are not individually discernible (e.g., there are no discernable grain boundaries), or that the grains have no discernible long-range order when viewed magnified by at least 100000 times magnification, such as with electron backscatter diffraction (EBSD) or other high-resolution microscopy such as Transmission Electron Microscopy (TEM) or Scanning Electron Microscopy (SEM). Alternatively, amorphous, as used herein, is used to mean that the coating comprises grains having an average grain size that is less than 20 nanometers (nm). Grain size can be measured as the longest length of the individual grain or based upon the total perimeter of the grain. In embodiments, by way of non-limiting example, the grain size or grain boundary size can be less than 5 nm.

The coating 32 can include a hardness. In one non-limiting example, the hardness for the coating 32 can be greater than 500 kilograms per millimeter² (kg/mm²), while a range including greater than or equal to 500 (kg/mm²) and less than or equal to 800 (kg/mm²) is contemplated. The hardness can be a Vickers Hardness, in a non-limiting example, which can be measured by applying a load or force to the coating 32 and determining size of indentation into the coating 32, such as using a Vickers Pyramid Number or Diamon Pyramid Hardness. Additionally, the hardness may be a Knoop hardness, which can be measured by indentation of a diamond tip into the coating 32, a Brinell hardness measured by a hardened steel or carbide ball with a known diameter indenting the coating, or Rockwell hardness measured by a diamond cone or hardened steel ball applied at two loads and recording measured depth.

The amorphous nature of the coating 32 provides for greater or improved hardness, as compared with a similar component with a non-amorphous coating, or including grain sizes or boundary sizes that have long-range order or are greater than 20 nm. Furthermore, the coating 32 has an improved hardness, which permits the use of a thinner coating 32, compared to a component using a non-amorphous coating. Using a thinner coating 32 reduces overall component weight, as well as increasing or improving resistance to erosion or corrosion. Additionally, the amorphous nature of the coating 2 provides improvements or increases to water and ice resistance are realized, such that water and ice formation along the coating 32 are decreased or minimized, as well as improvements to bonding among the coating and the underlying component.

In additional non-limiting examples, the coating 32 can be a nickel-phosphorous, nickel-tungsten, nickel-diamond, or other alloys. In such examples, the cobalt sulphamate can be replaced with phosphorus, tungsten, or diamond, or sulfates or sulphamates thereof, in order to achieve different hardnesses and weights for the coating. The particular hardness, weight or mass, or other material properties for the coating 32, can be varied by varying the materials used to form the coating 32, while still retaining the amorphous nature of the coating 32. Such variation can be used to achieve a certain hardness, stiffness, elasticity, coefficient of thermal expansion, melting point, or material content, in non-limiting examples, while decreasing material and manufacture costs.

Furthermore, utilizing electrodeposition results in atomistic bonding between the cathode 16 and the coating 32. Specifically, during electrodeposition, the coating 32 is formed on an atomic level by bonding individual atoms or molecules, one-by-one, to form the coating 32. Atomistic forming of the coating 32 onto the cathode 16 improves the bond among the coating 32 and the cathode 16. An improved bond can increase lifetime of the coating 32, and therefore, increased lifetime for the component 30, as well as reduced maintenance for the component 30. Therefore, it should be appreciated that the coating 32 provides for an improved bond, in addition to improved hardness resulting from the amorphous nature of the coating 32. The improved hardness and bond provides for an improved coating, having greater durability. Additionally, electrodeposition is not as capital intensive as other processes, such as rapid quenching or vapor deposition, and the coating 32 as described herein can reduce manufacturing costs, as well as reduce maintenance and related costs.

FIG. 3 is a flowchart illustrating a method 100 of electroforming a component, such as the component 30 of FIG. 2 having the coating 32 provided on the cathode 16, in accordance with various aspects described herein. The method 100 can further include, at 102, preparing a bath tank having an electrolytic solution, such as the electrodeposition tank 10 of FIG. 1. Preparing the bath tank can include preparing the electrolytic solution within the bath tank, such as the electrolytic solution 12 of FIG. 1. In one example, the electrolytic solution 12 can include greater than or equal to 40% and less than or equal to 70% nickel sulfamate (H₄N₂NiO₆S₂), greater than or equal to 1% and less than or equal to 15% cobalt sulfamate (CoH₄N₂O₆S₂), and greater than or equal to 20% and less than or equal to 50% deionized water, where percentages are by total volume of the electrolytic solution 12. Additionally, the electrolytic solution 12 can further include greater than or equal to 0.1 and less than or equal to 10 milliliters (ml) of a paraffin additive, or a wetting agent, such as a wetting agent for nickel sulfamate or cobalt sulfamate solutions. In one non-limiting example, Barrett Snap-L can be utilized. Additionally, the electrolytic solution 12 can further include greater than or equal to 0.01 grams per liter and less than or equal to 50 grams per liter of boric acid (H₃BO₃), greater than or equal to 0.01 grams per liter and less than or equal to 10 grams per liter of saccharin (benzoic sulfimide, C₇H₅NO₃S), and greater than or equal to 0.01 grams per liter and less than or equal to 1 grams per liter of phosphorus acid (H₃PO₃), where liters represent the total volume of the electrolytic solution 12. Further still, the voltage applied to the electrolytic solution 12 can be greater than or equal to 0.5 volts and less than or equal to 5.0 volts, the bath pH can be greater than or equal to 2 and less than or equal to 6, and the temperature can be greater than or equal to 35° C. or less than or equal to 65° C.

The method 100 can further include, at 104, pretreating the cathode 16. Pretreating the cathode 16 can include, in non-limiting examples, treating, providing, or otherwise preparing the cathode 16 for electrodeposition within the electrodeposition tank 10. For example, the cathode 16 can be at least partially covered by a non-conductive material, such as the non-conductive coating 38 (FIG. 2) to prevent electrodeposition along portions of the cathode 16. In another example, the cathode 16 can be cleaned or treated, in anticipation of electrodeposition of another material onto the cathode 16. In yet another example, the cathode 16 can be at least partially made from a sacrificial mandrel, intended to be removed from the cathode 16 after electrodeposition.

The method 100 can further include, at 106, positioning the cathode 16 within the electrodeposition tank 10 and electrolytic solution 12. Positioning the cathode 16 can include arranging the cathode 16 within the electrodeposition tank 10, as well as connecting the power source 18 via the electrical conduits 20 (FIG. 1).

The method 100 can further include, at 108, electrodepositing a coating onto the cathode 16 as an amorphous coating, such as the coating 32 (FIG. 2). Running an electric current through the electrolytic solution 12 causes deposition of materials from the anode 14 and/or the electrolytic solution 12 onto the cathode 16 to form the coating 32. Electrodeposition results in molecular or atomic bonding among the coating 32 and the cathode 16, resulting in improved bonding attachment among the cathode 16 and the coating 32. The coating 32 can be a nickel-cobalt phosphate (NiCoP), while alternatives can include nickel phosphorous, nickel cobalt, nickel tungsten, or nickel diamond in non-limiting examples.

The method 100 can further include, optionally, at 110, removing a mandrel, or other finishing-type processes, such as polishing or painting. In an example where the cathode 16 includes a removable mandrel. For example, the removable mandrel can be melted or leached from the cathode 16.

The method 100 can further include, at 112, inspecting the component 30 and/or the coating 32 provided thereon. Inspection can include determining that electrodeposition of the coating 32 has occurred as intended, such as achieving an intended local thickness. Additionally, inspection can include testing of the component 30, such as determining a hardness of the component 30 at the coating 32. In another example, the coating 32 can be measured, such as measuring grain size or long-range order of grains forming the coating 32. Electron backscatter diffraction (EBSD), for example, can be used to measure the coating 32 and the resulting grain sizing and arrangement. Additional non-limiting examples of measurements that can be made for the coating 32 can include hardness, elasticity, tensile strength, shear strength, grain size, grain boundary size, or grain order analysis. Hardness can be measured as a Vickers hardness, a Brinell hardness, a Knoop hardness, or a Rockwell hardness. The elasticity can be measured as a linear elasticity, and can be measured in units of pascal (Pa). The tensile strength can be measured as an ultimate tensile strength or yield strength, measured in mega-Pascals (MPa), that withstands stretching or pulling prior to breaking. The shear strength can be measured as an average shear stress across the coating 32. The grain size, grain boundary size, or grain order analysis can be measured with electron backscatter diffraction (EBSD) or other high-resolution microscopy such as Transmission Electron Microscopy (TEM) or Scanning Electron Microscopy (SEM), in non-limiting examples.

The voltage applied to the electrolytic solution 12 can be greater than or equal to 0.5 volts and less than or equal to 5.0 volts, the bath pH can be greater than or equal to 2 and less than or equal to 6, and the temperature can be greater than or equal to 35° C. or less than or equal to 65° C.

Aspects of the present disclosure provide for a variety of benefits. Particularly, an amorphous coating as described herein provides for improved or greater hardness for the coating, as well as improved or enhanced corrosion and erosion resistance. This provides for increased component lifetime, which reduces costs and maintenance. Furthermore, the greater hardness, corrosion resistance, and erosion resistance can be appreciated while utilizing a thinner coating than would be permitted by relatively lesser hardnesses or resistances. In this way, the amorphous coating can provide for a reduction in materials, which can reduce system weight, which can increase overall efficiency of the system incorporating the component having the coating. Additionally, the coating is both hydrophobic and ice-phobic. Hydrophobicity can be measured through analysis of drop size or movement during a tilt test, and ice-phobicity can be measured as a function of ice adhesion strength under force, such as with a centrifuge test.

Furthermore, the electrodeposition as described herein provides for atomistic bonding among the cathode and the coating, which provides greater adhesion between the cathode and the coating than other bonding methods. The greater adhesion increases component resiliency and lifetime, which reduces maintenance time and cost. Furthermore, the electrodeposition permits formation of the coating having no grains, grains with no long-range order, average grain sizes that are less than 20 nanometers, or average grain sizes that are less than 5 nanometers.

To the extent not already described, the different features and structures of the various embodiments can be used in combination with each other as desired. That one feature cannot be illustrated in all of the embodiments is not meant to be construed that it cannot be, but is done for brevity of description. Thus, the various features of the different embodiments can be mixed and matched as desired to form new embodiments, whether or not the new embodiments are expressly described. All combinations or permutations of features described herein are covered by this disclosure.

This written description uses examples to disclose the disclosure, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Further aspects of the disclosure are defined by the following clauses:

A method of forming a turbine engine component, the method comprising:

• • electrodepositing a coating onto a cathode submerged within an electrolytic solution, wherein the cathode is the turbine engine component, and wherein the electrolytic solution comprises: 40-70% by volume nickel sulphamate; 1-15% by volume cobalt sulphamate; 20-50% by volume deionized water; 0.1-10 milliliters per liter of a wetting agent; 0.01-50 gram per liter of boric acid; and 0.01-1 grams per liter of phosphorus acid; wherein the coating is amorphous defined by the coating comprising no discernable grains or the coating comprising grains with average grain size less than 20 nanometers.

The method of any preceding clause wherein the coating has no discernible grain boundaries.

The method of any preceding clause wherein the coating has no discernible long-range order.

The method of any preceding clause wherein the grain boundaries are less than 5 nanometers.

The method of any preceding clause wherein the coating is a nickel-cobalt phosphate.

The method of any preceding clause wherein the electrolytic solution contains greater than or equal to 0.01 grams per liter and less than or equal to 10 grams per liter of saccharin.

The method of any preceding clause wherein electrodeposition further includes passing a voltage through the electrolytic solution, wherein the voltage is greater than or equal to 0.5 volts and less than or equal to 5 volts to the electrolytic solution.

The method of any preceding clause wherein a pH of the electrolytic solution is greater than or equal to 2 and less than or equal to 6.

The method of any preceding clause wherein a temperature of the electrolytic solution is greater than or equal to 35° C. and less than or equal to 65° C.

The method of any preceding clause wherein a hardness of the coating is greater than 500 kilograms per square millimeter (kg/mm²).

The method of any preceding clause wherein the cathode is aluminum.

The method of any preceding clause wherein the wetting agent is a paraffin additive.

The method of any preceding clause wherein the turbine engine component is a fan blade.

The method of any preceding clause wherein the coating comprises a thickness that is greater than or equal to 1 micrometer and less than or equal to 75 micrometers

A composition for an electrolytic solution comprising: 40-70% by volume nickel sulphamate; 1-15% by volume cobalt sulphamate; 20-50% by volume deionized water; 0.1-10 milliliters per liter of a wetting agent; 0.01-50 grams per liter of boric acid; and 0.01-1 grams per liter of phosphorus acid.

The composition of any preceding clause wherein the electrolytic solution is provided in a system having a power source is configured to provide greater than or equal to 0.5 volts and less than or equal to 5 volts to the electrolytic solution.

The composition of any preceding clause wherein a pH for the electrolytic solution is greater than or equal to 2 and less than or equal to 6.

The composition of any preceding clause wherein a bath temperature for the electrolytic solution is greater than or equal to 35° C. and less than or equal to 65° C.

The composition of any preceding clause wherein the electrolytic solution further comprises greater than or equal to 0.01 grams per liter and less than or equal to 10 grams per liter of saccharin.

A component comprising: a cathode; and a coating electrodeposited onto the cathode, wherein the coating is amorphous, having grain sizes that are less than 20 nanometers.

The component of any preceding clause wherein the grain sizes are less than 5 nanometers.

The component of any preceding clause wherein the coating has no discernible grain size.

The component of any preceding clause wherein the grain sizes have no discernible long-range order.

The component of any preceding clause wherein the cathode is made at least partially of aluminum.

The component of any preceding clause wherein a hardness of the coating is greater than 500 kg/mm2.

The component of any preceding clause wherein the coating is a nickel-cobalt phosphate.

The component of any preceding clause wherein the coating comprises a thickness from greater than or equal to 1 micrometer to less than or equal to 75 micrometers.

The component of any preceding clause wherein the coating is hydrophobic.

The component of any preceding clause wherein the coating comprises nickel, chromium, tungsten, or molybdenum.

The component of any preceding clause wherein the coating comprises additional non-amorphous materials.

The component of any preceding clause wherein a Vickers hardness of the coating is greater than 500 kg/mm2.

The component of any preceding clause wherein the coating comprises a thickness that is greater than or equal to 1 micrometer and less than or equal to 75 micrometers.

The component of any preceding clause wherein the surface is aluminum.