1. OVERVIEW OF KINETIC METALLIZATION
PROCESS, EQUIPMENT, & APPLICATIONS
Inovati
Dr. RalphTapphorn, VP ofTech.
Howard Gabel, President
1501 Cook Place
Santa Barbara, CA 93117
www.inovati.com
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2. KINETIC METALLIZATION™ (KM)
COATING APPLICATIONS
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3. • Impact Consolidation Process
• Feed-stock: fine powder,
• Accelerant: inert light gas
• Solid-state Consolidation
• No Melting
• No Liquid Chemicals
• Environmentally Innocuous
• No Particle release
• No Chromate formation
• No Hazardous Gas Emission
• Enhanced worker safety
Substrate

4. RANGE OF KM COATING APPLICATIONS
Coatings on
HSS or Al
Alloy Parts
Al-Based Ni-Based Ti-Based WC-Based
Corrosion
Resistant
CP-Al
Al-Trans®/Cr Inconel-625
Ti
Ti-6-4 WC-7%Ni
Wear Resistant
Al-alloy +
~70vol%
SiC, B4C,WC
Inconel-625 +
~70vol%
SiC, B4C,WC
Cp-Ti +
~70vol%
SiC, B4C,WC
WC-17%Co
Dimensional
Restoration of
Parts
6061Al
6061Al/Ni alloy
7075Al/Ni alloy
Inconel-625
Inconel-718
Alloys
Ti
Ti-6-4
Alloys
WC-17%Co
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5. Gas Storage System
Thermal
Conditioning Unit
Powder
Fluidizing
Unit
KINETIC METALLIZATION™
PROCESS
US Patent 7,273,075
US Patent 6,915,964
Powder Preheater
Mixing Chamber
Friction Compensated
Sonic Deposition Nozzle
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6. KM-PCS SYSTEM
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7. POWDER FLUIDIZING UNITS
• Patented Brush-Sieve Design
• Light-weight pressure vessel
• Powder/ Gas flow rate independent
• Powder Size: 500nm - 50µm
• Feed Rate: 0-100g/min
• Large Capacity - 4 hour run time
• Dual PFU’s on KM-PCS 7

8. FRC-SW F/A-18
HYDRAULIC GEAR SHAFT
REPAIR
AMAD - Aircraft Mounted Accessory Drive
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9. REPAIR OVERVIEW
Hydraulic Pump Spur Gear
• Wear at sealing surface (AMS 6265)
• High Cost
• Low Part Availability
Current Repair
• Hard Chrome Plating
• Human Health & Environmental Issues
KM Repair
• NoToxic Chemicals
• Better PerformanceThan Original Part
FA-0008-14
3/10/2014
Page 6 of 9
THIS REPORT MAY NOT BE REPRODUCED, EXCEPT IN FULL, WITHOUT THE WRITTEN PERMISSION OF THE MATERIALS ENGINEERING DIVISION
NI MATLAB AP-008-A (10/12)
FOR OFFICIAL USE ONLY
Figure 3. Photograph of in-service gear (OEM) after 22 hours of accelerated testing.
Arrows point to damaged area on shaft (fine grid lines are 0.1inch).
Figure 4. Close-up photographs showing OEM shaft before (on the left) and after testing.
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10. DAMAGED HYDRAULIC GEAR
• 0.005” deep wear
groove • Detail
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11. 11

12. WC-CO MICROSTRUCTURE
KM WEAR RESISTANT COATINGS
HSS
•Fine grain structure (2-5 micron particle size)
•Tunable hardness — (%) hard phase
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13. KM Repair F/A-18E/F
Hydraulic Pump Gear Shaft
Wear damage removed and replaced
with WC-Co using
Kinetic MetallizationTM
Hv = 800Hv = 384
AMS 6265 WC-Co
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14. ACCELERATED WEARTESTING
Hours of
Accelerated Wear
Surface
Roughness (Ra)
(μ-in) Before
Surface
Roughness (Ra)
(μ-in) After
OEM Gear
AMS 6265
22 18-20 >200
Chrome Plate 21 4-5 >200
KM WC-Co 61 2-3 16-17
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15. FRC-SW F/A-18 (AMAD)
DIMENSIONAL RESTORATION
HYDRAULIC PAD
FRETTING DAMAGE
AMAD - Aircraft Mounted Accessory Drive
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16. 16
Severely fretted AMAD hydraulic pad KM Repair of AMAD in Spray Cabinet
Hydraulic pad surface, post KM spray Hydraulic pad post machining and NDI inspection
!
Alignment!pin!installed,!awaiting!NDI,!alodine!4conversion!coating!and!final!cleaning!prior!to!completion.!
!
!
Pad!surface,!post!spray!with!all!masks!except!alignment!pin!Teflon!plug!removed.!
!
!
S/N$241$Hydraulic$Pad$Fretting$Damage$$ $ $ $ $ $ 12/15/2010$
$
Hydraulic$pad$was$severely$fretted.$North$Island$removed$alignment$pin$and$machined$off$damaged$areas.$
(approximately$0.008$deep)$
$

17. FRC-SW F/A-18
DIMENSIONAL RESTORATION
BRAKE CARRIER
CORROSION DAMAGE
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18. 18
KM Repair F/A-18E/F Brake Carrier
1. Corroded and damaged surface machined down.!
2. Surface prepared by grit-blast for KM Repair.!
3. Kinetic Metallization repair as deposited.!
4. KM repair as machined.
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