ALUMINUM FILMS HAVING HARDENING PARTICLES

摘要

The described embodiments relate generally to aluminum layer and methods for forming aluminum layer onto metal substrates. Methods involve increasing the hardness of the aluminum layers by embedding hardening particles therein. According to some embodiments, hardening particles are co-deposited with aluminum onto a substrate using an electroplating process. The electrolytic process involves using an electrolytic bath having the hardening particles dispersed therein. The hardening particles can form a supportive network within the aluminum layer that increases the hardness of the aluminum layer. In some embodiments, a portion of the aluminum layer is converted to aluminum oxide.

主权项

1. A method for forming a hardened aluminum layer on a substrate, the method comprising:
exposing at least a portion of a surface of the substrate to a mixture of aluminum ions and hardening particles, the hardening particles characterized as having an average particle size larger than an average particle size of the aluminum ions; creating a flow of aluminum ions by causing at least a portion of the aluminum ions to move toward the substrate surface upon applying an electric field to the mixture; and creating a flow of hardening particles by causing at least some of the hardening particles to flow toward the substrate surface in accordance with the flow of aluminum ions, wherein at least a fraction of the aluminum ions from the flow of aluminum ions and at least a fraction of the hardening particles from the flow of hardening particles aggregate on the substrate surface forming an aggregate of aluminum metal and hardening particles on the substrate surface, the aggregate having a hardness value greater than that of aluminum metal.