Electrolytic Hard Chrome (EHC) coatings produce hazardous waste but tougher regulations are driving alternatives like HVOF and Kinetic Metallization. Kinetic Metallization is a low-temperature, low-pressure deposition technology that can coat surfaces EHC and HVOF cannot. It produces tungsten carbide coatings with tunable hardness, near-zero porosity, and adhesion strength greater than EHC. Kinetic Metallization has been approved by NAVAIR for repair coatings and is saving $2.2 million per year while meeting environmental standards.

1. Electrolytic Hard Chrome (EHC) is widely used for wear resistance coatings
within the defense, automotive, industrial equipment, electronics, and civilian
aircraft marketplaces. However, it produces a significant hazardous waste
stream of known carcinogens. Tougher OSHA regulations and penalties for
disposal of these waste products are driving the interest in developing an
alternative to this process. Many groups have turned to HVOF for hardness
coatings, but HVOF has its own drawbacks. HVOF operates at over 6,000ºF
and requires a special room in order to protect the operator. Kinetic
MetallizationTM (KM) is the future of EHC replacement. The KM process is a
low pressure, low temperature deposition technology that is revolutionizing
the coatings industry. The low temperature of the KM process precludes
decarburization of WC based coatings, increasing the resilience of these
protective surfaces when compared with
other thermal spray techniques. Low
temperatures reduce the chances of
damaging the substrate or its heat
treatment, this allows the KM process to
coat surfaces that no other process can.
Inovati has developed the KM HF
coatings for hardfacing components with
Kinetic Metallization. Some of the KM HF
coatings are Tungsten Carbide–Cobalt
(WC-Co) or Tungsten Carbide–Nickel
(WC-Ni) based. These coatings can
attain surface hardnesses greater than
EHC or HVOF coatings. Inovati’s WC
based coatings have the potential to
INOVATI PO Box 60007 Santa Barbara, CA 93160 (805) 571-8384 www.inovati.com
Benefits
• ES&H Compliant
• Low Cost
• ISO 9001 Compliant
• Low Temperature
• Low Pressure
• Quiet
• No Explosive Gas
• No Decarburization
KM HF Coatings
• Tunable Hardness
• Near Zero Porosity
• High Adhesion Strength (>10ksi)
• Low Thermal Degradation
• Field Repairable
Application Areas
• Hard Chrome Replacement
• Temperature Sensitive Materials
• Small Parts
• Wear Resistance
• Fatigue Resistance
• Dimensional Restoration
• Corrosion Protection
Kinetic Metallization
Hard Chrome Replacement
0.001-.050 Inches Thick | Metallurgical Bond | Low Porosity | ES&H Compliant
Kinetic Metallization Repair of a Gear Shaft with WC-Co Before (Left) and After (Right)

2. change the entire field of wear resistance. KM HF coatings have excellent
microhardness, which can be adjusted to suit your needs, and adhere with a
bond strength greater than that of EHC. Because of Inovati’s choice of particle
size, deposition temperature, and sonic gas velocity, the KM process creates
exceptionally wear-resistant surfaces.
Kinetic Metallization is trusted and approved by NAVAIR for dimensional
restoration and hardfacing of repair components for the F/A-18. Kinetic
Metallization is saving NAVAIR an estimated $2.2 million per year while
helping meet environmental regulations. They have just started to realize the
potential of KM and continue to fund the development of KM hardfacing and
repair operations at fleet readiness centers.
Kinetic Metalization is the safe, low temperature, proven alternative to EHC.
Inovati is the sole manufacturer of Kinetic Metallization equipment and is
proud to offer both developmental and production equipment packages that
can be configured to meet our customer’s needs. Please visit inovati.com or
call us at (805) 571-8384 for more information.
INOVATI PO Box 60007 Santa Barbara, CA 93160 (805) 571-8384 www.inovati.com
Characteristics of KM Tungsten Carbide - Cobalt Surface Coatings Compared With
HVOF Tungsten Carbide - Cobalt and EHC Surfaces
Inovati’s Kinetic Metallization Typical HVOF Electrolytic Hard Chrome
Hardness 700 - 1500 HV 700 - 1200 HV 800 - 1000 HV
Field Repairable Optional portable field unit Varies No
Thickness 0.001 - 0.050” 0.001 - 0.025” 0.0001 - 0.02”
Environmental and Health
Concerns
Cobalt or Nickel Cobalt, Air Pollutants
Hexavalent Chromium* used
extensively
Porosity <1% <1 - 5% <1 - 3%
Bond Strength > 10,000 psi >10,000 psi ~10,000 psi
Corrosion Resistance 1000 hours G85 Salt Fog 400 hours G85 Salt Fog** 500 hours G85 Salt Fog**
Temperature Effects Negligible Apparent Negligible
*IARC, International Agency for Research on Cancer, Group 2B Material - Possible Carcinogen
**http://db.materialoptions.com/ASETSDefense/SEDB/EHC_Alts/Qual_Eng_Data/Reports/HVOF%20on
%20Helicopter%20Components%20DRAFT%20Final%20Report.pdf
***http://www.asetsdefense.org/documents/Workshops/17thCadmiumPlatingMeeting/30-Lee%20Stellite
%20Corrosion%20Measurements.prn.pdf