Copyright UCT Defense LLC, 2003 Page 1 UltraCem TM 5 th Generation Nickel Boron To Replace Chromium...

Copyright UCT Defense LLC, 2003

UltraCemTM

5th Generation Nickel BoronTo Replace Chromium Plating

Presented to HCAT by Chuck McComas

April 2003

Advancing the Science of Metal Finishing Technology Advancing the Science of Metal Finishing Technology for Defense Applicationsfor Defense Applications


• 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

Metal Finishing Technologies for:

• Defense

• Armaments

• Aerospace

• Ground Vehicles

• Maritime

• Forestry

• Foundries

• Industrial Pumps

• Molds & Tooling

• Oil & Gas

UCT Defense – A Joining of Forces


• 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

Characteristics of UltraCemTM


Structure of UltraCemTM

Nodular growth with true metallurgical bond.


Cross Cut Gear

Complete Uniformity

Uniformity of UltraCemTM

Due to the electroless plating process, UltraCem plates at a very high degree of Uniformity.


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%

Thallium 2.5%-6.0% --

Cobalt 0.0-2.0% --


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)(Magnification 500x)

Evolution of Nickel-Boron

Earlier generations of Nickel-Boron coatings had a high degree of voids, leading to reduced corrosion resistance and sheer strength.


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


Environmentally-Friendly Process

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

Plating Characteristics


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

NiB Plating Procedure

Operating Procedure


Superior Wear Resistance


Low Coefficient of Friction


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.


PEWG – CIP – November 2003 Bath Analysis

Bath Chemistry, Including Heavy MetalsDeposit Chemistry

Basic Properties of DepositBond StrengthHardness TestingWear ResistanceHydrogen Content

Comprehensive Laboratory ValidationPratt & WhitneyGeneral ElectricRolls Royce

Estimated Cost $235K

Pratt & Whitney Proposed NiB for Chromium Replacement


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 1 UltraCem TM 5 th Generation Nickel Boron To Replace Chromium...

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