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With our wide range of technical expertise, Mohawk Metallurgical Associates materials and metallurgical engineering professionals can efficiently solve individual client problems in many areas including:
- Failure Analysis of a wide variety of materials and applications
- High Temperature Materials and Coatings Performance Analysis
- Process Optimization
- Diffusion Coatings
- Repair of IGT and Aeroderivative Components
- Chemical Cleaning and Stripping
- Thermal Spray Coatings
- Corrosion Evaluation and Mitigation
•Failure Analysis:
We have failure analysis capability for:
• Hot section gas turbine components including buckets, nozzles, and combustion systems
• Compressor blades, stator vanes, and many other gas turbine components
• Steam turbine rotating and stationary components
• Pipes, valves, and fittings especially associated with the power generation, petrochemical and paper industries
• Boilers, heat recovery steam generators
• Coatings - organic, inorganic, metallic, ceramic
• O-rings and gaskets
Failure mode identification, evaluation of the metallurgical state of materials and coatings in both failed and non-failed areas, and suggestions for avoidance of similar problems will constitute, as appropriate, the output of such analyses.
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•High Temperature Materials and Coatings Performance Analysis:
Mohawk Metallurgical Associates can perform metallurgical analysis of serviced components which will provide information relative to the continued serviceability of the parts as well as recommendations for a repair or replacement workscope. MMA can also provide estimates of remaining coating life, the ability of the materials to perform satisfactorily under the imposed operating conditions, and suggestions of possible alternatives where this is not the case.
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•Consulting for Process Optimization:
Our staff consultants have had extensive experience in process optimization for the following fields:
• High temperature materials and processing
• High temperature brazing including wide-gap and TLP techniques
• Diffusion bonding and weld repair of high temperature alloys
• Diffusion coating including aluminides, chromides and modified aluminides
• Thermal spray coatings including HVOF, LPPS, and APS techniques
• Pre-braze repair cleaning including aqueous and fluoride ion cleaning techniques
• Chemical stripping of aeroderivative and IGT coatings
• Electrocleaning and electropolishing
• Electroplating of nickel, chromium, platinum, and palladium
We can provide process consultation services and project management for development projects, pilot and manufacturing operations, supplier quality audit, and process qualifications.
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•Consulting for Diffusion Coatings:
MMA has had extensive experience in the development, testing, and production of various diffusion coatings including aluminides, chromides, and aluminides modified by chromium, platinum, palladium and silicon. We also have extensive expertise with pack cementation, static and dynamic vapor phase delivery systems, CVD, and slurry methods. Our staff consultants can efficiently troubleshoot existing processes and provide critical evaluation of all aspects of diffusion coatings including process development, production, and pre and post-service condition.
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•Consulting for Repair of IGT and Aeroderivative Components:
Our staff has had extensive experience in the repair of industrial gas turbine (IGT) and aeroderivative jet engine hot zone and compressor components. This includes writing repair workscopes and process procedures. We have experience providing cost-effective solutions in the following areas:
•Casting issues
•Chemical stripping processes
•Electrocleaning processes
•Mechanical material removal
•Restorative thermal treatments
•Braze repair
•Weld repair
•Recoating by HVOF, LPPS and diffusion methods
•Life assessment of repaired components
We have performed site visits and laboratory investigations to support these analyses.
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•Consulting for Chemical Cleaning and Stripping:
Mohawk Metallurgical Associates has extensive experience in development, testing, and writing specifications for various types of aqueous chemical cleaning and stripping processes primarily associated with, but not limited to new and serviced IGT and aeroderivative hot zone components.
Our process expertise includes:
•Removal of oxides and hot corrosion products
•Chemical stripping of serviced coatings by mixed mineral acids and other methods
•Electrocleaning and electropolishing
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•Consulting for Thermal Spray Coatings:
Expert thermal spray services include consultation for:
•Thermal spray process and coating development
•Coating selection and application development
•Troubleshooting of coating and processing problems
•Metallurgical evaluation of serviced thermal spray coatings
Our knowledgeable staff is experienced with thermal spray techniques such as wire arc, plasma, HVOF, and LPPS, as well as the equipment and systems manufactured by the major international thermal spray equipment companies. Our experience covers robotic and traditional application of a wide variety of thermal spray coatings, including metallic, ceramic, and cermet type coatings used for anticorrosion, tribological, part restoration, and thermal barrier purposes.
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•Corrosion Evaluation and Mitigation:
In conjunction with extensive failure analysis experience, our materials engineers can help identify the causes of corrosion being encountered and provide suitable cost effective recommendations to mitigate industrial corrosion problems including:
•Aqueous corrosion - pitting, crevice, galvanic, erosion-corrosion
•High temperature oxidation and gaseous corrosion
•Atmospheric corrosion
•Environmentally assisted cracking - stress corrosion cracking,corrosion fatigue
Mitigation of the environmental degradation of metallic and nonmetallic materials may be achieved through alternative material selections, surface modifications, environmental chemistry changes, and/or product configuration changes. Consultation services and program management for corrosion testing and evaluation of projects can also be provided.
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