What We Do
Consulting Services
From advanced powder processing technology set-up and ramp-up to various coating application and operations support, and production-floor support — every engagement is grounded in materials and advanced processing science.
Materials & Coatings Development
We design, develop, and optimize coating systems from the ground up — selecting the right material chemistry, deposition process, and properties/microstructure for your specific operating environment. Whether you need a new thermal barrier system, a wear-resistant cermet overlay, a new advanced dielectric coating or a corrosion-protective coating, we bring the full depth of advanced processing science — thermal spray, weld over/laser cladding, brazing, PVD, CVD, and beyond — to the specification.
Typical Deliverables
Coating specification, process parameter documentation, characterization report, qualification test plan
Capabilities
- Thermal spray coating system design (APS, HVOF, HVAF, and Wire Arc)
- Coating property optimization
- Process parameter development and qualification
- Coating characterization and performance testing
- Material selection for extreme temperature, wear, and corrosion environments
- Transition from lab-scale to production process
Powder Development — Ceramic
Ceramic powders are the foundation of thermal barrier coatings, erosion/wear-resistant coatings, and dielectric layers across aerospace, IGT, and semiconductor applications. We develop and characterize ceramic feedstock powders — including YSZ, alumina, chromia, and specialty oxide systems — optimizing particle chemistry, morphology, size distribution, phase composition, and flowability for your specific deposition process.
Typical Deliverables
Powder specification sheet, characterization data package, process qualification report and production ready compliance
Capabilities
- YSZ, alumina, chromia, and specialty oxide powder development
- Hollow sphere (HOSP) and dense morphology optimization
- Particle size distribution and flowability characterization
- Phase composition analysis (XRD)
- Spray-drying and sintering process development
- Powder qualification for APS and HVOF processes
Powder Development — Metallic & Cermet
Metallic and cermet powders — WC-Co, Cr3C2-NiCr, MCrAlY, and custom alloy systems — require precise control of composition, morphology, and microstructure to perform in demanding service environments. We develop and qualify these feedstocks from composition design through full characterization, ensuring consistent deposition behavior and coating performance.
Typical Deliverables
Powder specification, composition and microstructure data package, deposition trial report, property testing and production ready compliance report.
Capabilities
- WC-Co, Cr3C2-NiCr, and custom cermet system development
- MCrAlY and bond coat alloy powder engineering
- Agglomerated & sintered and clad powder morphology development
- Composition verification (EDS, WDS, ICP)
- Hardness, porosity, and microstructure characterization
- HVOF and HVAF process qualification
Failure Analysis
When a coated component fails in service, the root cause is rarely obvious. We conduct systematic failure investigations — combining visual examination, SEM/EDS analysis, cross-section metallography, and mechanical testing — to identify the precise mechanism and origin of failure. Our reports are written for both technical and management audiences, with clear findings and actionable recommendations.
Typical Deliverables
Failure analysis report with root cause determination, supporting data, and corrective action recommendations
Capabilities
- Visual and stereomicroscopic examination
- SEM/EDS microstructural and compositional analysis
- Cross-section metallography and coating microstructure evaluation
- Fractography and fracture surface analysis
- Hardness mapping and mechanical property assessment
- Corrosion, oxidation, and wear mechanism identification
Condition Assessment
In-service components accumulate damage through thermal cycling, oxidation, erosion, and mechanical fatigue. We evaluate the current condition of coated and uncoated components — quantifying degradation, estimating remaining service life, and recommending maintenance or refurbishment strategies. Our assessments help operations teams make data-driven decisions about repair, replacement, and inspection intervals.
Typical Deliverables
Condition assessment report with degradation quantification, remaining life estimate, and maintenance recommendations
Capabilities
- In-service coating degradation assessment
- Remaining life estimation for thermal barrier and wear coatings
- Oxidation and hot corrosion damage quantification
- Erosion and wear mapping
- Refurbishment feasibility evaluation
- Inspection interval and maintenance strategy recommendations
R&D Support
R&D programs in advanced processing and materials move faster with a specialist embedded in the team. We provide technical consulting, experimental design, data interpretation, and reporting support for internal R&D programs, government-funded projects, and university collaborations. Whether you need a subject matter expert for a specific phase or a long-term technical partner, we adapt to your program structure.
Typical Deliverables
Technical reports, experimental data packages, process documentation, and program milestone implementation and other support
Capabilities
- Experimental design and test plan development
- Advanced processing development and optimization
- Materials characterization and data interpretation
- Technical report writing and documentation
- IP landscape review and prior art analysis
- Collaboration with OEMs, national labs, and universities
Process
How We Engage
Every engagement follows a structured process — from initial scoping through final deliverables.
Discovery Call
We start with a focused technical conversation to understand your challenge, timeline, and success criteria.
Scope & Proposal
We define the work scope, deliverables, and timeline in a clear written proposal — no ambiguity.
Execution
We conduct the analysis, development, or assessment work with regular progress updates.
Deliverables & Review
Final reports and data packages are delivered with a review session to walk through findings and recommendations.
Have a specific challenge in mind?
Tell us about your project and we'll scope the right engagement.