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Coating compositions, coatings, coated parts and methods of use of chromate/phosphate type compositions. The coating compositions are of a type which contains small spheroidal aluminum particles having a defined size. The coated materials of the invention having improved corrosion and erosion resist

Coating compositions, coatings, coated parts and methods of use of chromate/phosphate type compositions. The coating compositions are of a type which contains small spheroidal aluminum particles having a defined size. The coated materials of the invention having improved corrosion and erosion resistance and improved low profile.

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1. A coating composition especially suitable for coatings which have improved surface profile, corrosion resistance, erosion resistance and which are capable of faster curing and becoming electrically conductive more rapidly, which coating composition comprises (a) and aqueous acid binder solution w

1. A coating composition especially suitable for coatings which have improved surface profile, corrosion resistance, erosion resistance and which are capable of faster curing and becoming electrically conductive more rapidly, which coating composition comprises (a) and aqueous acid binder solution which comprises phosphate ions and ions selected from the group consisting of chromate and molybdate ions, and (b) a powder which comprises atomized aluminum spheroids having an average particle size (measured in ESD) not larger than about 4 microns. 2. The coating composition of claim 1 wherein the particle size is not larger than about 3 microns. 3. The coating composition of claim 1 wherein the particle size is in the range of about 3 to about 4 microns. 4. The coating composition of claim 1 wherein at least 60 percent by weight of the spheroids is less than about 4 microns. 5. The coating composition of claim 1 wherein at least 50 percent of the spheroids is less than about 4 microns and at least 30 percent of the spheroids is less than about 3 microns. 6. The coating composition of claim 1 wherein at least 10 percent of the spheroids is less than about 2 microns. 7. The coating composition of claim 1 wherein not more than about 20 percent by weight of the spheroids is larger than about 5 microns. 8. The coating composition of claim 1 wherein at least about 30 percent of the spheroids is not larger than about 3 microns. 9. The coating composition of claim 1 wherein the atomized aluminum spheroids are non-oxidizing gas atomized aluminum. 10. The coating composition of claim 9 in which the atomized aluminum spheroids are inert gas atomized spheroids. 11. The coating composition of claim 1 wherein the powder includes aluminum alloy particles. 12. The coating composition of claim 1 wherein the powder further comprises a refractory compound selected from the group consisting of a carbide or a nitride of boron, silicon or titanium. 13. The coating composition of claim 1 wherein the aluminum powder is selected from the group of powders consisting of A and B, powder A and B having a particle size distribution, respectively, as follows: [TABLE] ______________________________________ Powders A B ______________________________________ Less than 10 micron 96% 96% Less than 7 micron 92% 85% Less than 6 micron 88% 78% Less than 5 micron 80% 67% Less than 4 micron 65% 52% Less than 3 micron 44% 32% Less than 2 micron 17% 10% ______________________________________ and an average ESD of 3.2 and 3.9, respectively. 14. The coating composition of claim 13 wherein the aluminum powder is powder A, with said particle size distribution and average ESD. 15. The coating composition of any one of claims 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, or 14 which has a viscosity in the range of about 600 to about 50,000 cp. 16. A dry coating composition especially suitable for coatings which have improved surface profile, corrosion resistance, erosion resistance and which are capable of faster curing and becoming electrically conductive more rapidly, which coating composition comprises (a) a spray dried binder which comprises phosphate and an inorganic compound of the group consisting of chromate, molybdate and the metal salts thereof, and (b) a powder which comprises atomized aluminum spheroids having an average particle size (measured in ESD) not larger than about 4 microns. 17. A coating composition especially suitable for coatings which have improved low surface profile, smooth surface, improved corrosion and erosion resistance and which are capable of faster curing and becoming electrically conductive more rapidly, which coating composition comprises (a) an aqueous acid binder solution which comprises phosphate ions and ions selected from the group consisting of chromate or molybdate ions, and (b) a powder which comprises atomized aluminum spheroids of which at least about 52 weight percent and having an average particle size (measured in ESD) not larger than about 4 microns. 18. The coating composition of claim 17 wherein at least about 65 weight percent of the aluminum spheroids [have a] particle size (measured in ESD) is not larger than about 4 microns. 19. The coating composition of one of claims 17 or 18 wherein the spheroids are non-oxidizing gas-atomized aluminum spheroids. 20. The coating composition of one of claims 17 or 18 wherein the spheroids are inert gas-atomized spheroids. 21. The dry coating composition of claim 16 wherein the aluminum spheroids have an average particle size not larger than about 3 microns. 22. The dry coating composition of claim 16 wherein the aluminum spheroids have an average particle size in the range of about 3 to 4 microns. 23. The dry coating composition of claim 16 wherein at least 60 percent by weight of the spheroids is less than about 4 microns. 24. The dry coating composition of claim 16 wherein at least 50 percent of the spheroids is less than about 4 microns and at least 30 percent of the spheroids is less than about 3 microns. 25. The dry coating composition of claim 16 wherein at least 10 percent of the spheroids is less than about 2 microns. 26. The dry coating composition of claim 16 wherein not more than about 20 percent by weight of the spheroids is larger than about 5 microns. 27. The dry coating composition of claim 16 wherein at least about 30 percent of the spheroids is not larger than about 3 microns. 28. The dry coating composition of claim 16 wherein the atomized aluminum spheroids are non-oxidizing gas-atomized aluminum. 29. The dry coating composition of claim 16 in which the atomized aluminum spheroids are inert gas-atomized spheroids. 30. The dry coating composition of claim 16 in which the powder includes aluminum alloy particles. 31. The dry coating composition of claim 16 wherein the powder further comprises a refractory compound selected from the group consisting of a carbide or a nitride of boron, silicon or titanium. 32. The dry coating composition of claim 16 wherein the aluminum powder is selected from the group of powders consisting of A and B, powder A and B having a particle size distribution, respectively, as follows: [TABLE] ______________________________________ Powders A B ______________________________________ Less than 10 micron 96% 96% Less than 7 micron 92% 85% Less than 6 micron 88% 78% Less than 5 micron 80% 67% Less than 4 micron 65% 52% Less than 3 micron 44% 32% Less than 2 micron 17% 10% ______________________________________ and an average ESD of 3.2 and 3.9, respectively. 33. The coating composition of claim 32 wherein the aluminum powder is powder A, with said particle size distribution and average ESD.