Meta-Structured Cermets for Chrome Replacement

The objectives of this Phase I project are to demonstrate the production of potentially very low-cost nano/metastructured thermal spray powders using recycled scrap tools or very low-cost ceramic powders and to demonstrate superior materials properties of the metastructured coating when applied using thermal spray. The result would be a new class of very low-cost, nanostructured cement coatings that can displace chrome and cadmium plating for controlling metal corrosion and wear. A successful Phase I outcome would develop a commercial market for scrap ceramic tool materials and would provide a completely nonhazardous replacement for chrome plating. It also would eliminate pollution caused by surface preparation techniques that are used currently in thermal spray. The proposed program is designed to replace toxic chrome plating, because of new regulatory limits on exposure to hexavalent chrome and disposal costs associated with chrome use. The primary commercial market lies in heavy equipment and automotive applications, including hard chrome replacement on hydraulic cylinder, bulldozer blades, ball and needle valve seats, motor shafts, mining drill bits, and mining equipment. Other potential industrial machinery applications also exist.