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NICKO-FUSE TECHNOLOGY DEVELOPMENT Justin Cheney, PhD CTO April 28, 2011

NICKO-FUSE TECHNOLOGY DEVELOPMENT Justin Cheney, PhD CTO April 28, 2011. NICKO-FUSE: Capability for un - paralleled corrosion resistance exceeding thermal spray or weld overlay performance Implemented in extremely corrosive environments Nickel-based alloys

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NICKO-FUSE TECHNOLOGY DEVELOPMENT Justin Cheney, PhD CTO April 28, 2011

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  1. NICKO-FUSE TECHNOLOGY DEVELOPMENT Justin Cheney, PhD CTO April 28, 2011

  2. NICKO-FUSE: • Capability for un - paralleled corrosion resistance exceeding thermal spray or weld overlay performance • Implemented in extremely corrosive environments • Nickel-based alloys • High degree of microstructural and property control • Utilizes standard commercially processes • No dilution, no heat affected zone • High adhesion strengths, strong metallurgical bond

  3. CORROSION RESISTANCE: ELIMINATING PERMEABILITY Treated* Hastelloy C276 Twin Wire Arc Spray Coating Treated* Nicko-Fuse Twin Wire Arc Spray Coating Only Nicko-Fuse can be treated to form non-permeable coatings with economical techniques * Commercial Vacuum Brazing Operation

  4. COATING INTEGRITY .03” .03” Hastelloy C276 Twin Wire Arc Spray Coating Permeable Low Adhesion Nicko-Fuse Coating Non-Permeable High Adhesion Nicko-Fuse Technology is Being Developed to Eliminate the Disadvantages of Thermal Spray

  5. COATING INTEGRITY .03” .05” Inconel 622 MIG Weld Overlay Heat Affected Zone / Substrate Embrittlement Long Dendritic Grains Iron Dilution into Overlay Nicko-Fuse Coating No Heat Affected Zone Controlled Grain Size/None Dendritic 0% Iron in Coating Layer Nicko-Fuse Technology is Being Developed to Eliminate the Disadvantages of Weld Overlay

  6. MICROSTRUCTURAL CONTROL X Ray Diffraction Spectrum of Coating Nicko-Fuse forms a singles phase austenitic Ni-structure: CTE matching carbon steel Elevated Cr and Mo levels known to resist chlorides and other corrosive media Austenitic Nickel

  7. TECHNICAL DATASHEET Applications: Extremely Corrosive Environments (Boilers) Adhesion: 10,000 psi (ASTM C633) Melting Temperature: 2150oF (1175 oC) Porosity: < 3% Oxide Content: <3% Corrosion Resistance: Excellent Similar or Superior to Alloy C276 Particle CTE: 13 x 10-6 Permeability: Very Low Chemical Composition: Ni Bal Si <5% B<5% Cr <35% Mo<20% Other<5% Recommended Parameters: TAFA 8830/8835 Atomizing Air Pressure: 50-75 psi Nozzle Cap: Green Nozzle Positioner: Long C Arc Load: 29-32 V Current: 175-250 A Coating Thickness Per Pass: 1.2-1.3 mil Coating Texture: < 300 μ-inch Spray Rate: 16 lbs/hr. Deposition Efficiency: <70% Wire Size: 1/16” Coverage: 0.7 oz/ft2/0.001”

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