[0001] The present invention relates to a method for preparing a durable electrode material
usable as an insoluble anode usable for electrolysis in a bath containing chlorine
compounds and sulfur compounds, which comprises coating a current-conductive material,
such as titanium, with a metal diffusion film such as of a metal of the platinum group.
[0002] In electroplating of a continuous steel strip using a soluble electrode, the concentration
of metal ions in the electroplating bath gradually increases due to the difference
between the deposition efficiency of the cathode which is usually from 94% to 97%
and the dissolution efficiency of the anode which is usually from 100% to 103%. In
order to maintain the metal ion concentration in a proper range, it has been a common
practice according to the prior art that the soluble anode is partially replaced by
an insoluble anode so as to control the concentration of the metal ion, and at the
same time, to cause deposition of the metal for a desired amount of electroplating
so as to optionally control the metal ion concentration.
[0003] Therefore, in the prior art using an insoluble anode, it is necessary to alternately
pass and cut the current and the electrode must be durable in order to perform the
electroplating satisfactorily.
[0004] Also in electroplating of a continuous steel strip using a soluble anode, the amount
of dissolution of the anode varies from portion to portion of the electrode, thus
differing between the right side and left side of the electrode, and between the upper
portion and the lower portion of the electrode. For example, this dissolution amount
changes when the relative distance between the anode and the cathode changes or when
the electrical resistance in the current path changes. Therefore, it is necessary
to maintain a considerable distance between the cathode and the anode. However, the
distance is usually 25 mm to 35 mm,' and the loss of energy by the bath resistance
is large.
[0005] In order to obtain constant electroplating conditions, it is necessary to maintain
the insoluble anode dimensionally stable, to maintain a shorter electrode distance
so as to obtain a uniform metal deposition, and to lower the required voltage.
[0006] Further, in the electroplating using a soluble anode, for example, a tin anode, 200
to 300 cast tin anodes, each weighing about 10 kg, are used in one electroplating
line.
[0007] The anodes must be supplemented to make up for the consumption (dissolution) of the
anodes. Therefore, repeated heavy labour and complicated handling-in or handling-out
of the anodes for such supplementation are required.
[0008] Also for eliminating the heavy labour and the complicated handling of the anodes,
the anode must be insoluble.
[0009] Therefore, there is an increasing demand for insoluble anodes suitable for electroplating
of continuous steel strips.
[0010] Notwithstanding only lead-based anodes have been used in commercial practice as a
non-corrosive anode for electroplating in sulfuric acid baths, with some-exceptions
where titanium electrodes coated with 3 to 5 micron platinum, are used, but other
materials have been found to be unsuccessful in practical use due to their inferior
durability and dissolution of impurities into the electrolyte.
[0011] In the case of lead-based anodes, they are undesirable for tin-plating of beverage
cans, etc., from the toxicologic aspect, and have disadvantages in zinc-plating in
general that the zinc coating peels off during the paint baking due to the presence
of very small amounts of Pb ions and that the color and brightness of the coating
are deteriorated by the chromate treatment. Therefore, electrode materials have been
required which can prevent the dissolution of impurities into the electrolyte and
do not deteriorate the coating quality.
[0012] Under such a situation, there is a demand for a method for the production of insoluble
anodes which can meet various requirements as above.
[0013] Concerning insoluble anodes, the following prior art references are relevant:
[0014] Japanese Patent Publication No. Sho 38-10515 discloses an insoluble anode prepared
by electroplating a titanium base with platinum, heating this coated material at a
temperature not lower than 400°C in an inert gas or in vacuum of not higher than 10
-5 mmHg to alloy the titanium base with the platinum coating.
[0015] Japanese Patent Publication No. Sho 39-20910 discloses a method comprising electro-deposition
of platinum in a thickness of 2 to 3 micron on a base material, heating in an inert
gas in the temperature range from 400°C to 800°C, surface activating treatment, and
further platinum plating in a thickness of 3 to 5 micron.
[0016] Japanese Patent Publication No. Sho 48-43267 (1973) discloses the preparation of
non-corrosible electrodes which comprises inpinging rare gas ions on to the surface
of a titanium cathode, coating the surface of the titanium cathode with a metal of
the platinum group in an atmosphere substantially free from oxygen, and further applying
a coating of ruthenium oxide on the platinum coating.
[0017] Japanese Patent Publication No. Sho 49-7789 discloses a method of producing anodes
for electrolysis which comprises electroplating of platinum or rhodium in a thickness
of 0.2 micron or more on the electrode base, further electroplating with ruthenium,
and firing at a temperature not lower than 500°C in an oxidizing atmosphere.
[0018] The important technical object of these prior art anodes is to obtain better adhesion
of the platinum coating and to eliminate defects of the coated film.
[0019] It has been found, however, that the base materials such as titanium are converted
into nitrides and oxides when heated to 600°C or higher, so that their mechanical
strength and current conductivity are lowered. On the other hand, when they are heated
to temperatures lower than 600°C, the alloying between platinum and the titanium base
and between the platinum coating and ruthenium is very poor and only partial.
[0020] Therefore, these prior art anodes have the defect that it is impossible to select
a proper condition which can produce a desirable alloyed layer and at the same time
can prevent the oxidation and nitrization of the base material.
[0021] Further, Japanese Patent Publication No.Sho 48-3954 discloses an electrode in which
the oxide of a metal selected from the platinum group consisting of platinum, iridium,
rhodium, ruthenium and osmium is used.
[0022] Japanese Patent Publication No. Sho 45-11014 discloses a method for electrolysis
of an aqueous solution of alkali metal chlorides which comprises electrolysing the
solution with an anode potential of 1.36V or lower using an anode made of an alloy
of 20% to 50% platinum and 80% to 50
% palladium or an anode coated with the alloy.
[0023] The above-mentioned prior art references are directed to an anode material which
is cheaper than platinum and can stabilize the oxygen overvoltage.
[0024] However, when oxides of platinum group metals or platinum group metals are to be
directly coated on titanium base material and the like, no or only partial alloying
with the titanium base material is obtained at the temperatures which cause the thermal
decomposition of the chlorides and nitrides in the case of oxide films and platinum
films, so that titanium oxide appears at non-coated portions.
[0025] The prior art insoluble anodes have been chiefly used in the chloralkali electrolysis,
and although these prior art anodes can satisfactorily stand for the electrolysing
conditions in a chlorine bath, such as electrolysis of sodium chloride, these prior
art anodes have been found to have very little durability in a metal electroplating
in a sulfuric acid bath, for example, which is performed under intermittent electrolysing
conditions, because oxide films . such as TiO
2 filmsreadily dissolve. due to their reverse position in the electromotive force series.
[0026] According to the prior art for plating platinum or a metal of the platinum group
on an electrode base material, such as titanium, only a thin platinum film with many
pin holes can be obtained, so that the electrode base material dissolves from the
coating defects (pin holes) into the electrolyte and rapidly promote the consumption
of the platinum coating.
[0027] Also in the pretreatment for platinum plating, mechanical surface conditioning, such
as sand blasting and shot blasting are sometime performed. In such cases, the sands
or shots are blasted into the titanium base, or the surface oxide scale is forced
into the base metal so that pin holes or pin hole like non-coated portions are caused
in the platinum coating. These can be a vital defect to the life of the electrode.
[0028] In order to prevent these coating defects, trials have been made to give a thicker
platinum coating on the base metal or to perform the electroplating in a two-step
manner, but it has been almost impossible to completely eliminate the non-coated portions,
because the electro-precipitation of a coating metal follows the electro-precipitation
nuclei of the base metal.
[0029] Thus, the insoluble anodes to be used for continuous electroplating of steel strips,
such as in tin-plating in ferrostan baths and halogen baths, and in zinc-plating in
chloride baths and sulfuric acid baths must stand for various electrolysing conditions
including the current passing methods, and the bath compositions. Thus the prior art
anodes have been unsuccessful in electroplating of steel strips.
[0030] Therefore, the object of the present invention is to provide an insoluble anode satisfactorily
usuable in continuous electroplating of steel strips and to provide a method for preparation
thereof.
[0031] According to the present invention, an insoluble electrode with a coating film free
from defects can be obtained.
[0032] The features of the present invention lie in that a current conductive material is
coated with at least one metal of the platinum group by electroplating, then a compound
or salt of the platinum group metals, such as Ir, Ru, Ph and Pt is applied on the
coating previously applied and is decomposed by heating in a reducing or non-oxidizing
atmosphere to make up defects of the electroplated coating. At the same time, a metal
of the platinum group which is active at the thermal decomposition of the salt is
diffused into the electroplated coating at a temperature not higher than 600°C to
avoid nitrization of the base metal. In this way, an electrode coated with a metal
of the platinum group and having a continuous, thin diffusion film is obtained.
[0033] According to a modification of the present invention, a further coating of a metal
and/or oxide of the platinum group may be applied by electroplating or non-electrolytic
coating on the thermally diffused coating.
[0034] Regarding the reducing atmosphere for thermal decomposition of the compound or salt
of the platinum group metals in the present invention, it includes a reducing flame,
and an atmosphere containing a reducing gas, such as hydrogen and carbon monoxide.
While the non-oxidizing atmosphere includes an inert gas, such as nitrogen gas, desirably
in the form of gas stream. Ordinary inert gases contain. a small amount of oxygen,
and the thermal decomposition can be satisfactorily done in a gas stream containing
up to 1000 ppm of oxygen as usually contained in a device or furnace for maintaining
the inert gas atmosphere. However, it is preferable to perform the thermal decomposition
under presence of not more than 100 ppm oxygen.
[0035] The platinum group metals used in the present invention include the elements belonging
to the 8th group of the Periodic Table. Among these elements platinum is easiest to
electroplate.
[0036] The present invention will be described by reference to the attached drawings.
[0037] Brief Explanation of the Drawings:
Fig. 1 schematically shows the cross section of an electrode according to the present
invention.
Fig. 2 shows a graphical analysis of the cross. section of the electrode shown in
Fig. 1 by an electron probe micro analyzer - EPMA - (scanning A).
Fig. 3 shows a graphical analysis of the cross section of the electrode shown in Fig.
1 by EPMA (scanning B).
Fig. 4(a) is a photograph showing the secondary electron image (prior to electrolysis)
of the surface of the electrode electroplated with 1 micron platinum by EPMA; and
Fig. 4 (b) is a photograph showing PtLa characteristics X ray.
Fig. 5(a) shows the secondary electron image of the surface of the electrode electroplated
with 1 micron platinum (prior to electrolysis) by EPMA; and Fig. 5(b) shows PtLa characteristics
X ray.
Figs. 6(a) - (f) show the progress of deterioration of an insoluble titanium anode
electroplated with platinum (x40).
Fig. 7(a) shows the secondary electron image of 1 micron platinum coating diffused
with 1 micron Ru-Rh-Ir by EPMA.
Fig. 7(b) shows the PtLa characteristics X ray of the coating in Fig. 7(a).
Fig. 8(a) shows the cross section of a titanium electrode electroplated with 1 micron
platinum after 70 hours of continuous electrolysis.
Fig. 8(b) is a graphical analysis of the cross section in Fig. 8(a).
Fig. 9(a) showsthe cross section of a titanium electrode electroplated with platinum
and diffused with Ru-Rh-Ir prior to electrolysis; and Fig. 9(b) shows the graphical
analysis of the cross section of the same.
Fig. 10 shows the polarization of a conventional anode electroplated only with 1 micron
platinum.
Fig. 11 shcws the polarization of an anode electroplated with 1 micron platinum and
diffused with 1 micron Ir-Rh-Ru.
Fig. 12 shows the weight loss by time of the anode according to the present invention during
electrolysis.
[0038] The following description of the present invention will be made in connection with
a preferred embodiment in which platinum coating is applied by electroplating.
[0039] For preparing the insoluble anode of the present invention, the titanium base material
is acid-pickled to clean the surface, coated with platinum by a conventional method.
[0040] The bath composition for the electroplating of the platinum group metals, various
bath compositions may be used, such as an ammonia alkali bath containing diamine platinum
nitrite. A typical bath composition and plating conditions are shown below:

[0041] The thickness of the electroplated coating must be at least 0.1 micron. In the case
of the platinum coating, the coating defects still remain even if the thickness is
increased as described hereinbefore. Therefore, from the . aspect of economy, it is
desirable to maintain the coating thickness up to 3 micron. The most desirable range
is from 0.2 to 1.0 micron.
[0042] Then a solution of chloride of Ir-Ru-Rh in ethylalcohol, butyl-alcohol or propyl-alcohl,
dispersed in a reducing organic solvent such as lavender oil and/or terpene oil (oil
of turpentine) is applied on the platinum coating, dried and thermally decomposed
(40 cycles for 1 micron coating; each cycle comprises drying and thermal decomposition)
at a temperature in the range from 380°C to 600°C preferably from 400°C to 550°C under
reducing flames..
[0043] The concentration of various metal compounds may be varied within their dissolution
range, but a preferable range is from 0.01% to 0.1%.
[0044] The application of the solution may be done by immersion, spraying or roll brushing.
Regarding the proportions among Ir, Ru, Rh and Pt, a higher corrosion resistance can
be obtained by a larger proportion of Ir and Pt. For example, 60% Ir - 20% Ru - 20%
Rh (by weight) is preferable. The thickness of coating required for making up the
coating defects must be 0.1 micron at least, and a preferable range is from 0.2 to
1.0 micron.
[0045] 'The thermal decomposition is performed by passing the coated electrode through the
reducing flames at a speed of about lm/minute. After the thermal decomposition, the
electrode is heated at about 500°C to 600°C, preferably 500°C to 550°C in an oxidizing
atmosphere for about one hour to take away non-decomposed chlorine. In this way, the
final anode can be obtained.
[0046] As the base material for the anode according to the present invention, titanium alloys,
tantalum, tantalum alloys, zirconium and zirconium alloys may be used in addition
to titanium.
[0047] Other than chlorides of the platinum group metals, such as Ir, Ru and Rh, an aqueous
solution of one or more of compounds of the platinum group elements, such as NO, N0
2 NOC1 compounds may be used. In short, these elements may be in any form which is
soluble in water or other solvent.
[0048] Fig. 1 shows the cross section of an electrode according to the present invention.
This electrode was prepared by electroplating a titanium base 3 with 1 micron platinum,
then applying to this electroplated titanium base a coating of a chloride of Ir, Rh
and Ru and thermally decomposing the chloride under reducing flames. The diffusion
film 1 of Ir-Ru-Rh is formed at the portion at which the platinum coating is made.
Meanwhile, at the coating defects, such as pin holes, the film 2 formed by the thermal
decomposition of the chlorides of Ir, Ru and Rh makes up the coating defects.
[0049] As shown in Fig. 2 showing the EPMA graphical analysis of the cross section of the
above anode, Ir, Rh and Ru are diffused into the platinum coating, and as shown in
Fig. 3, the diffusion film of Ir-Ru-Rh formed by the thermal -decomposition is present
at the portion where no platinum coating is present, namely the defect of the platinum
coating.
[0050] As shown in Fig. 1, the coating on the titanium base obtained by the process of the
present invention has a diffusion structure of Ir-Ru-Rh and of Pt-Ir-Ru-Rh free from
pin holes.
[0051] For application of two or more metals of the platinum group on the electroplated
platinum coating, two or more solutions of salts of the platinum group metals may
be simultaneously applied, or a first solution of one salt of the platinum group metal
is applied and heated, and then a second solution of another salt is applied and heated.
In this way, a plurality of the platinum group metals can be diffused simultaneously
or one after another successively to form an alloyed layer which covers the pin holes
of the electroplated coating. In either way, an electrode having excellent corrosion
resistance can be obtained.
[0052] Regarding the coating or film formed by the thermal decomposition of the compound
or salts of the platinum group metals, it is necessary that the application of the
solution, and the heating are repeated until a desired thickness of the coating or
film can be obtained, because a single application of the solution and thermal decomposition
gives only a very thin coating or film although it depends on the concentration of
the solution. As mentioned hereinbefore, 40 cycles of application of the solution
and heating are required for obtaining 1 micron coating or film.
[0053] Further, although a single cycle of electroplating . and repeated salt application
and thermal decomposition can give a satisfactory corrosion resistance of the coating,
when the cycle is repeated twice or more, a.very excellent surface coating extremely
free from the pin holes can be obtained because the electroplating followed by the
thermal decomposition coating is performed on the surface activated by the thermal
decomposition.
[0054] If the electroplating and the non-electrolytic coating are repeated, better results
can be obtained when they are repeated more times for the purpose of eliminating the
pin holes, although there is no specific limitation therefor. Basically the more desired
result can be obtained by repeating the electroplating and the non-electrolytic coating
under the specified conditions. For example, an electrode having very little pin holes
can be obtained a total thickness of 0.8 micron composed of by electroplating of 0.2
micron platinum, diffusion coating of 0.2 micron platinum group metal, and electroplating
of 0.2 micron platinum. The electroplating coating may range from 0.1 to 1.0 micron
in thickness, and the diffusion coating may range from 0.02 to 1.0 micron in thickness.
[0055] Thus, according to the present invention,-a coating of a platinum group metal diffused
with a platinum group metal, which is extremely free from pin holes, can be obtained
by the combination of the electroplating of a platinum group metal and the thermal
decomposition of a compound or salt of a platinum group metal.
[0056] The coating according to the present invention shows very excellent corrosion resistance
as compared with the conventional electroplating or spray coating of a platinum group
metal alone. This excellent corrosion resistance can still be improved by the following
modification of the present invention.
[0057] Thus after the electroplating of the platinum group metal, salt of the platinum group
metal, such as Ir, Ru, Rh, Pt is applied on the electroplated coating and thermally
decomposed in a non-oxidizing atmosphere so as to cover the defect portions of the
coating, and further one or more metals of the platinum group is electroplated or
coated by non-electrolytic method and/or an oxide film is formed to provide a multiple-layer
coating. In this way, the corrosion resistance can be still enhanced.
[0058] When the upper-most coating is applied by electroplating, the underlying coating
layer is already a pin-hole free coating of a platinum group metal, so that it is
easy to obtain a continuous coating having good adhesion under . conventional electroplating
conditions.
[0059] When the upper-most coating layer of a multiple coating is applied by a non-electrolytical
method and thermal decomposition, compounds of the platinum group metals are applied
and thermally decomposed in a reducing or substantially non-oxidizing atmosphere to
deposit the metals, part or whole of which is diffused into the underlying coating.
Further, the upper-most layer may be partially or wholly of oxide. In this case, also
satisfactory adhesion and corrosion resistance can be obtained. The oxide can be formed
by heating the metal after deposition in an oxidizing atmosphere, or by bringing the
deposiaed metal into contact with an oxidizing atmosphere during the thermal decomposition
step. Further, the oxide may be applied by spattering. The oxide may be an oxide of
a platinum group metal, or an oxide of a metal other than the platinum group, such
as titanium oxide and zirconium oxide, or a mixture of these oxides.
[0060] As described hereinabove, the most important feature of the present invention is
that the defects and disadvantages of the prior art have been solved by making up
the defects of the platinum coating by the formation of thermally decomposed product
and diffusion at relatively low temperatures of the thermally decomposed products
into the platinum coating for continuity with the platinum coating.
[0061] According to a modification of the present invention, the corrosion resistance of
the coating is improved by a multiple coating layer.
[0062] Various experiments have been made with the insoluble anodes according to the present
invention and the results will be explained in connection with the attached photographs
of the coating surfaces, the electron probe micro analysis (EPMA) of the surfaces
and the cross sections of the anodes.
[0063] In Fig. 4(a) showing the surface EPMA of the conventional titanium anode coated with
platinum by electroplating and Fig. 4(b) showing the characteristic X rays (PtLa)
of the platinum coating, the weakness of a single uniform film which is peculier to
the platinum electroplating produces the surface defects, and the non-deposition of
platinum is shown by the PtLa ccharacteristics X ray.
[0064] As shown in Fig. 5(a) showing the surface EPMA of the anode coated with platinum
coating in a thickness of 7 micron, and in
Fig. 5(b) showing the PtLa characteristics X ray, even if the coating thickness is
increased by 7 times, a larger film is retained so that when the electrolysis is carried
out intermittently, , particularly when the current passage is stopped, the base material
is dissolved and this dissolution causes the platinum coating to peel off from the
base metal.
[0065] In Fig. 6 showing the progress by time of deterioration of a titanium insoluble anode
coated with 3 micron platinum at the stages after 30 days, 45 days, 60 days, 75 days
and 90 days of electroplating, the peelings off of the platinum coating expand from
the coating defects until they connect to each other, thus increasing the non-conductive
portions on the electrode.
[0066] In Fig. 7(a) showing the surface EPMA of the anode according to the present invention
in which a mixture of salts of Ir, Rh and Ru is applied in an amount equivalent to
1 micron thick on 1 micron platinum coating, and thermally decomposed and diffused
into the platinum coating, and in Fig. 7(b) showing the PtLa characteristics X ray,
the salts of the platinum group elements diffuse into the electroplated platinum coating,
while there is almost no diffusion or alloying is seen between the electroplated platinum
coating and the base titanium.
[0067] Thus, as clearly shown by the attached drawings and photographs, the coating obtained
by the present invention is in fact a diffused and alloyed coating which is completely
free from defects and has excellent corrosion resistance.
[0068] The present invention will be better understood from the following embodiment..
[0069] The anode potentials of the titanium anode electroplated with platinum coating and
diffused with the platinum group elements according to the present invention before
and after electrolysis will be illustrated below.
[0070] In Fig. 10, the polarization of a conventional anode electroplated only with 1 micron
platinum is shown and in Fig.11 the polarization of an anode electroplated with 1
micron platinum and further with a diffusion layer of 1 micron Ir-Rh-Ru according
to the present invention.
[0071] No increase of the anode potential is seen before and after electrolysis in the case
of the anode according to the present invention (Fig. 11), and no substantial increase
of the anode potential is seen even at a high current density as 100 A/dm
2.
[0072] The loss of the anode weight during electrolysis is shown in Fig. 12. The electrolysis
was done under the following conditions.
[0073] The insoluble anode and the cathode made of iron were opposingly placed in a bath
containing 200 g/ℓ Na
2S0
4 with pH of 1.0 and the electrolysis was done at 50°C and 30
A/dm
2. The total weight loss of the anode was measured and the weight losses by hours were
shown.
[0074] When an electrode electroplated with 1 micron platinum and diffused with Ir-Ru-Rh
mixture according to the present invention is used (line 1) a weight loss of only
0.5 g/m
2 is observed even after 70'hour electrolysis, and also when an electrode electroplated
with 1 micron platinum diffused with Ir and electroplated with 0.5 micron platinum
according to the present invention is used (line 2), a weight loss of only 0.2 g/m
2 is observed even after 70 hour electrolysis. In both cases no substantial increase
in the voltage is seen.
[0075] While in the case of the conventional anode electroplated only with 1 micron platinum
(line 3), a loss of 3 g/m was observed after 56 hour electrolysis, which is about
6 to 10 times larger than the loss in the case of the anode of the present invention,
and a substantial voltage increase was caused after 56 hour electrolysis, thus prohibiting
a further electrolysis.
[0076] Further in the case of a titanium electrode electroplated with 1 micron platinum
and further coated with 3 micron platinum by three cycles of heating at 700°C in an
inert gas (line 4), a weight loss of 2.5 g/m
2 is observed after 56 hour electrolysis, which slightly less than the weight loss
in the case of the electrode electroplated with 1 micron platinum, but the voltage
increases after 56 hour electrolysis, thus prohibiting further electrolysis.
[0077] In the case of the titanium anode with a thermally decomposed Ru-Rh-Ir coating directly
applied to the base titanium (line 5), a loss of 10 g/m and also a voltage increase
were seen after 42 hour electrolysis, thus prohibiting a further electrolysis. The
weight loss of this anode is 20 to 30 times larger than the loss of the anode according
to the present invention. This means a shorter life of the anode.
[0078] As understood from the forgoing descriptions of the" embodiments of the present invention,
the electrode according to the present invention can be well used an insoluble anode
for electroplating of steel strips, but is also applicable to ordinary electroplating
and electrolysis industries.
[0079] As examples of application of the electrode according to the present invention to
the electroplating of steel strips, the electrode of the present invention may be
used as insoluble anodes in a vertical electrolytic tank having electrodes positioned
across the steel strip, or in a horizontal electrolytic tank having electrodes positioned
above and below the steel strip.
[0080] Also the electrode of the present invention can be used as an insoluble anode in
a horizontal, linear-type plating tank in which the electrolyte is forcedly circulated
at a high velocity between the steel strip and upper and lower in electrodes as disclosed
Japanese Patent Publication No. Sho 50-8020, or in a drum-type electrolytic tank in
which the electrolyte is forcedly circulated between the strip closely contacting
a drum immersed in the electrolyte and the electrodes arranged around the strip as
disclosed in U.S.Patent No. 3,483,113.