Transcript Proposed Agenda

Advancing the Science of Metal Finishing Technology
for Defense Applications
UltraCemTM
5th Generation Nickel Boron
To Replace Chromium Plating
Presented to HCAT by Chuck McComas
April 2003
Copyright UCT Defense LLC, 2003
Page 1
UCT Defense – A Joining of Forces
Metal Finishing Technologies for:
• Defense
• Armaments
• Aerospace
• Ground Vehicles
• Maritime
• Forestry
• Foundries
• Industrial Pumps
• Molds & Tooling
• Oil & Gas
Copyright UCT Defense LLC, 2003
• Special Operations
• Information Protection and
Assurance
• Digital Signal Processing
• Design and development
of process control and
instrumentation devices
• Radar design
• Environmental
technologies
• Technical analysis and
programmatic support
Page 2
Characteristics of UltraCemTM
•
Metallurgical bond
•
Dense nodular structure
•
Uniform deposition (99%) – sharp edges, bore holes,
complex part. No post grinding required
•
Provides lubricity – reduced coefficient of friction
•
Hardness values (1200-1400HK25)
•
Provides 3X wear resistance
•
Coating adheres to flexible substrates
•
Provides wear surface for ferrous, aluminum, titanium,
powdered metals
•
No hydrogen embrittlement
•
Heat tolerance to 1600 degrees F
Copyright UCT Defense LLC, 2003
Page 3
Structure of UltraCemTM
Nodular growth with true metallurgical bond.
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Page 4
Uniformity of UltraCemTM
Due to the electroless plating
process, UltraCem plates at a
very high degree of Uniformity.
Complete Uniformity
Cross Cut Gear
Copyright UCT Defense LLC, 2003
Page 5
NiB Plate Composition
PWA 259
Type I
Type II
Nickel
Balance
Balance
Boron
2.5-8.5%
2.5-5.0%
Thallium
--
2.5-6.0%
Cobalt
--
0.0-2.0%
AMS 2433B
Type I
Type II
Nickel
Balance
Balance
Boron
2.5-5.0%
2.5-8.5%
2.5%-6.0%
--
0.0-2.0%
--
Thallium
Cobalt
Copyright UCT Defense LLC, 2003
Page 6
Evolution of Nickel-Boron
Earlier generations of Nickel-Boron
coatings had a high degree of voids,
leading to reduced corrosion
resistance and sheer strength.
(Magnification 500x)
Copyright UCT Defense LLC, 2003
UltraCemTM (5th generation)
provides increased hardness and
wear resistance while providing a
high level of lubricity. Cubic inch
density is greatly increased
resulting in higher shear strength.
(Magnification 500x)
Page 7
Bath Characteristics of UltraCemTM
Bath Characteristics
Repeatable – 10-14 metal turn-overs
 Plating rate - .0006 to .0009 in./hr.
 Closed loop system
 Clean air environment
 Chemically strippable without substrate
damage

Copyright UCT Defense LLC, 2003
Page 8
Environmentally-Friendly Process
Plating Characteristics

Operates in closed-loop water system

Operation temperature 194° to 200° F

Alkaline solution – Ph 12-14

Disposal/recovery system substantiated

No thallium, ammonium, arsenic, or cyanides
Copyright UCT Defense LLC, 2003
Page 9
NiB Plating Procedure
Operating Procedure

Receive directional and visual inspection

Develop operation sheets

Mask areas not to be coated

Chemically clean

Chemically activate

Plate to desired thickness

Air bake 425° to 700 ° F
Copyright UCT Defense LLC, 2003
Page 10
Superior Wear Resistance
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Page 11
Low Coefficient of Friction
Copyright UCT Defense LLC, 2003
Page 12
UltraCem™ vs. Hard Chrome

Hardness: UltraCem: 1200-1400 HK, hard chrome: 950-1000 HK

Wear resistance: UltraCem provides significantly more abrasion and wear resistance
(3x) than hard chrome

Bond strength: UltraCem has a true metallurgical bond that exceeds all known pull tests:
>10,000 psi

Uniformity: coats uniformly 99.8%, including blind holes and recessed areas, large
internal diameters

Post treatment: requires no post-grinding and can be polished to low surface finish < 1
RMS

Lower energy costs: UltraCem has lower setup and operating costs, lower energy
consumption, no expense related to rectifiers and anodes, 3-4 times greater throughput
with same tank capacity

Ductility: UltraCem exceeds 180 degree bend test due to bond and unique columnar
structure

Coefficient of Friction: UltraCem .08, Hard Chrome: 1.3 - 1.35

Operating Temperature Tolerance: UltraCem can withstand operating temperatures to
+1,500o F, hard chrome starts to deteriorate at 800o.
Copyright UCT Defense LLC, 2003
Page 13
Pratt & Whitney Proposed NiB
for Chromium Replacement
PEWG – CIP – November 2003

Bath Analysis
Bath Chemistry, Including Heavy Metals
Deposit Chemistry

Basic Properties of Deposit
Bond Strength
Hardness Testing
Wear Resistance
Hydrogen Content

Comprehensive Laboratory Validation
Pratt & Whitney
General Electric
Rolls Royce

Estimated Cost $235K
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Page 14
Current DoD Activities

Air Force Propulsion Lab (PEWG)/Pratt & Whitney

Air Force Research Lab – Preliminary Evaluation

Air Force Special Operations Command (AFSOC)

Greaseless GunTM

US Army Picatinny

US Army Industrial/Ecology Center

NAVAIR Naval – Aviation – Pax River

Naval Surface Warfare Center - Crane
Copyright UCT Defense LLC, 2003
Page 15