Euclid, OH, United States
Euclid, OH, United States

MesoCoat, Inc. is a Euclid, Ohio based equit backed company providing metal protection and repair. MesoCoat develops and provides wear and corrosion solutions using surface engineering technologies, serving Oil and Gas, Aerospace, Energy, Infrastructure and other markets. Wikipedia.


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A heterogeneous composite body that is spall resistant and comprises a substantially discontinuous cermet phase in a substantially continuous metal rich matrix phase. The heterogeneous composite body is typically bonded to a substrate to form a hardfacing on the substrate. The heterogeneous composite body exhibits ductile phase toughening with a strain to failure of at least about 2 percent, a modulus of elasticity of less than about 35 million pounds per square inch, and a density of less than about 7 grams per cubic centimeter. The metal rich matrix phase between the ceramic rich regions in the heterogeneous composite body has an average minimum span of about 0.5 to 8 microns to allow ductility in the heterogeneous composite body. The heterogeneous composite body has a Vickers hardness number of greater than approximately 500. The ceramic rich regions exhibit high hardness as compared with the matrix phase.


Grant
Agency: National Aeronautics and Space Administration | Branch: | Program: SBIR | Phase: Phase I | Award Amount: 124.99K | Year: 2014

This program will develop a series of nano-/micro-composite coated nuclear reactor facing components using MesoCoat's CermaCladTM process. This proposed SBIR program will build on MesoCoat's extensive prior experience with high energy density fusion cladding systems for large area applications (pipe, plate, structures) where wear and/or corrosion limit the life of metal structures


Grant
Agency: National Aeronautics and Space Administration | Branch: | Program: SBIR | Phase: Phase I | Award Amount: 125.00K | Year: 2014

This program will develop low friction hard coatings for lubricating mechanical and tribological components used for exploring Mars, the Moon, asteroids, comets and other small bodies. This proposed SBIR program will build on MesoCoat's extensive prior experience in developing dense, hard friction-free coatings.


Grant
Agency: Environmental Protection Agency | Branch: | Program: SBIR | Phase: Phase II | Award Amount: 300.00K | Year: 2015

Every year, a significant amount of money is lost due to atmospheric attack of steel parts. A convenient and effective way for corrosion protection is coating the unalloyed steel with a thin layer of zinc (Zn) metal by galvanizing. Pickling is an essential step of this process to ensure high quality surface of steel for further processing. In this process, acid is used to remove scale from the surface containing oxides. When the acid concentration in the pickling solution decreases by 75-85% (by weight), the bath is dumped because the efficiency of pickling decreases with increasing content of dissolved metal. This dumping has a grave environmental impact such as high concentration of metals and acids in wastewater, and there is a genuine need to develop zinc coatings with an environmentally-friendly process that can replace the galvanizing pickling lines and the alkaline or acidic degreasing step prior to pickling. Additionally, this technology reduces the formation of zinc fumes which evolve from maintenance of a molten zinc bath as well as eliminating the formation of dross, waste iron-zinc alloy that is formed in the sheet galvanizing process. MesoCoat proposes developing zinc coatings having excellent corrosion resistance using their R&D100 award-winning CermaClad™ process, which uses a high-density infrared lamp to fuse a uniform layer of metal onto metal surfaces. The innovation marries breakthrough nanocomposite materials technology with breakthrough low impact, cost- effective, high-rate light fusion application technology. The high power density and large area nature of the fusion system enables these claddings to be applied at high rates. Furthermore, metal cladding eliminates the use and disposal of Volatile Organic Compounds (VOCs). Extending the life of steel parts through these advanced coatings by CermaCladTM will cut back on the need for new steel production to replace those products hence reducing associated carbon emissions. Main tasks involved are design and construction of a continuous foil and sheet coating rig, development of coating parameters, metallurgical characterization, performance evaluation and reporting. Successful application of these coatings can be applicable for corrosion protection of steel parts such as rebar, bridge decks, shipping, shipbuilding, hydroelectric, power generation, refineries, pipelines, railroads, grid transmission towers, oil/gas production and architecture.


Grant
Agency: Department of Energy | Branch: | Program: SBIR | Phase: Phase I | Award Amount: 149.31K | Year: 2012

Fusion energy has the ability to provide a greater source of energy with lower harmful byproducts than any energy producing device currently on the planet. In order to make the production of fusion energy more real, there is a genuine need for new and novel materials that will be able to handle the harsh plasma environment including high heat loads, sputtering, and radiation. MesoCoat proposes to develop a series of nano-/micro-composite coating materials to be applied to Plasma Facing Components using MesoCoat & apos;s high energy density fusion cladding process, CermaCladTM. The materials being explored include tungsten and molybdenum based coatings which will improve plasma performance and helium based cooling while minimizing thermal stresses and providing excellent corrosion resistance. Commercial Applications and other Benefits: The material system and process developed in this program will help advance the development of Fusion reactors, which will provide a new large and clean energy source to the world. Beyond the fusion energy applications these materials and the CermaClad process can be used in fission energy reactors, and in the chemical processing industries providing improved corrosion resistance and better mechanical properties at elevated temperatures


Patent
Mesocoat, Inc. | Date: 2016-10-07

The present invention concerns methods and apparatus for forming a clad product, such as a clad pipe or tube. Particular embodiments include a method for metallurgically bonding cladding material onto a metal substrate, the method including a step of providing a metal substrate comprising a pipe or a tube having a cladding composition arranged along an interior surface of the substrate to form a coated substrate, the interior surface arranged within an interior cavity of the substrate. A further step includes inserting a heat source into an interior cavity of the substrate, the heat source comprising an infrared, microwave, or radio frequency heat source, the heat source being mounted on a heat source-retaining housing, the housing comprising a cantilevered structure. An additional step includes applying heat discharged from the heat source to the coated substrate along the coated interior surface until the cladding composition metallurgically bonds to the substrate.


Grant
Agency: Department of Defense | Branch: Navy | Program: STTR | Phase: Phase I | Award Amount: 80.00K | Year: 2016

During Phase I, we propose to develop nanostructured, low friction thermal sprayed coatings that are able to withstand high dynamic loadings. Additionally, the novel coatings will possess a low friction coefficients in humid air, dried conditions and various greases and lubricants. These novel nanostructured coatings will be manufactured by HVOF spraying of solid lubricants based nanostructured powders.


Grant
Agency: Department of Health and Human Services | Branch: | Program: SBIR | Phase: Phase I | Award Amount: 148.87K | Year: 2014

DESCRIPTION: This Small Business Innovation Research Phase I project shows great intellectual merit. The antimicrobial properties of copper-based alloys continue to be a topic of research interest, and there are no current publications detailing the mechanical properties, corrosion resistance, and anti-microbial characteristics of copper-based alloy bi-layers. Pending a successful Phase I research program, high wear and corrosion-resistant copper alloys in the form of copper-based alloys will be evaluated.The broader impacts of this project are manifold. An inherently anti- bacterial coating for hospital applications has wide-ranging effects on degree of health care and mitigation of costs incurred through infection associated with hospital practice. Commonexamples include: infections from biomedical implants, degradation of protective coatings on buildings, fouling of food products, loss of efficacy of pharmaceutical formulations, and many more. A growing body of health literature is promoting the use


Grant
Agency: Environmental Protection Agency | Branch: | Program: SBIR | Phase: Phase I | Award Amount: 99.94K | Year: 2014

Every year, a significant amount of money is lost due to atmospheric attack of steel parts. A convenient and effective way for corrosion protection is coating the unalloyed steel with a thin layer of zinc (Zn) metal by galvanizing. Pickling is an essential step of this process to ensure a high-quality surface of steel for further processing. In this process, acid is used to remove scale from the surface containing oxides. When the acid concentration in the pickling solution decreases by 75–85 percent (by weight), the bath is dumped because the efficiency of pickling decreases with increasing content of dissolved metal. This dumping has a grave environmental impact, such as high concentration of metals and acids in wastewater, and there is a genuine need to develop zinc coatings with an environmentally friendly process that can replace the galvanizing pickling lines and the alkaline or acidic degreasing step prior to pickling. MesoCoat proposes developing zinc coatings having excellent corrosion resistance using their R & D100 award-winning CermaCladTM process, which uses a high-density infrared lamp to fuse a uniform layer of metal onto metal surfaces.The innovation marries breakthrough nanocomposite materials technology with breakthrough low-impact, cost­effective, high-rate light fusion application technology. The high power density and large area nature of the fusion system enables these claddings to be applied at high rates. Furthermore, metal cladding eliminates the use and disposal of volatile organic compounds (VOCs). Extending the life of steel parts through these advanced coatings by CermaCladTM will cut back on the need for new steel production to replace those products, hence reducing associated carbon emissions. The Zn layer can prevent corrosion of metals by forming a physical barrier and by acting as a sacrificial anode when the barrier is in danger. On exposure to atmosphere, Zn reacts with oxygen to form zinc oxide, which in turn reacts with carbon dioxide to form zinc carbonate and offers excellent corrosion resistance to the base material. In this project, process parameters will be optimized to control thickness, composition and properties of the protective Zn layer. The main tasks involved are sample preparation, coating application, metallurgical characterization, performance evaluation and reporting. Successful application of these coatings can be applicable for corrosion protection of steel parts, such as rebar, bridge decks, shipping, shipbuilding, hydroelectric, power generation, refineries, pipelines, railroads, grid transmission towers, oil/gas production and architecture.


The invention describes a method for producing ternary and binary ceramic powders and their thermal spraying capable of manufacturing thermal sprayed coatings with superior properties. Powder contain at least 30% by weight ternary ceramic, at least 20% by weight binary molybdenum borides, at least one of the binary borides of Cr, Fe, Ni, W and Co and a maximum of 10% by weight of nano and submicro-sized boron nitride. The primary crystal phase of the manufactured thermal sprayed coatings from these powders is a ternary ceramic, while the secondary phases are binary ceramics. The coatings have extremely high resistance against corrosion of molten metal, extremely thermal shock resistance and superior tribological properties at low and at high temperatures.

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