HI-T-LUBE®

A High-Technology "Synergistic" Coating ThatDramatically Prevents Friction, Galling, andWear — Even at Critical Temperature Extremes.

Although HI-T-LUBE “synergistic” coatings were used tosolve performance problems troubling critical metalparts on NASA’s space vehicles, engineers worldwidesoon recognized them as the solution to “down toearth” problems encountered by all types of manufac-turing, processing, and packaging equipment.

Magnaplate-applied HI-T-LUBE, listed in The GuinnessBook of Records as the world’s “slipperiest” solid (with aCOF of 0.03), is created in a proprietary, multi-stepprocess. It maintains excellent lubricity over a variety oftemperature extremes and withstands extremely highcompression loads. HI-T-LUBE also remains unchanged

in high vacuum applications. Unlike conventional lubri-cants, it will not outgas or accumulate in unloaded areas.Its dimensions can be controlled so that critical fits andexact clearances are maintained. Since the newly createdsurface of the part is superior in performance, both tothe substrate metal or to any of the individual engineeringpolymers or other components used in the process,HI-T-LUBE is identified as “synergistic.”

The selection of which polymers are used is based onmany factors, including: end-use application of the part,its base metal, the kind of hostile environments to whichit might be exposed, and the coating buildup permitted.

Examples of How HI-T-LUBE Coatings Solve Performance Problems

Pictured here is a small selection of thehuge number of different types of slidingor mating parts which exhibit dramaticimprovements in their performance properties after being treated with aMagnaplate-applied HI-T-LUBE coating.

„ Recognized by The Guinness Book of Records for the Lowest COF of Any Solid (0.03)

„ Can operate in vacuums of 10-7 Torr

„ Prevents abrasive wear and galling

„ Will not outgas in space environments

„ Withstands up to 200 hrs salt spray at .001” thickness

„ Excellent adherence to base metals, regardless ofchanges in temperature or environment

„ Withstands sliding and rolling loading at high/low temperature extremes

„ Vibration stable from 28G rms to 85G peak rms

„ Permanently dry self-lubricating for extended wear

„ Compatible with hydrocarbons and syntheticlubricants

„ Control of coating thickness is +/-.0003 at .001”

Each individual layer of the matrix in the diagram belowoffers beneficial features, and collectively, upon final diffusion, they form a metallic/oxide matrix that exceedsthe qualities of any one of the elements alone.

1. The base metal undergoes a proprietary pre-cleaningprocess. Special provisions are made to avoid hydrogenembrittlement of the metal.

2. An extremely hard, proprietary coating is applied tothe metallurgically cleaned surface. This layer forms thecritical interface and contributes to the hardness of thetotal matrix structure.

3. A malleable layer is applied. It is composed of metalsthat provide HI-T-LUBE with its high temperature resistanceand exceptional compressive properties.

4. A surface layer, composed of highly effective lubricants,is then applied.

5. The previously deposited layers are diffused in acontrolled atmosphere chamber.

High Loads and TemperaturesIn application testing for jet engine use, HI-T-LUBEproved its superiority under the most exacting condi-tions. In preliminary thrust bearing tests — from roomtemperature up to 1000°F (538°C), using an appliedload of 1400 pounds rotating at 720 rpm and reversingdirection every three seconds — where conventionallubricants and combinations of materials failed in lessthan five minutes, HI-T-LUBE performed effectively forthree hours (thirty-six times greater effectiveness).Additional verification of the uniqueness of HI-T-LUBEappears in a report from an aircraft manufacturer’sEngineering Dynamic Analysis Section: “...Further testswere run with other alloys and other lubricants, howevernone could meet the exceedingly high loads andtemperatures achieved by the combination of HaynesAlloy 25 and HI-T-LUBE.”PermanenceIn addition, the aircraft manufacturer’s report stated that:“...when a second set of Haynes bushings was treatedwith General Magnaplate’s HI-T-LUBE, the life was evenfurther extended to 849 cycles. However, this proprietaryhigh temperature dry lubricant was tried on the bushingand also the mating part of the lever and link into whichthe bushings were installed, and the life cycles jumpedup to 1302 cycles. This more than met the required lifespan of the parts.” In another series of tests, HI-T-LUBEcoated gears outperformed untreated gears by up to 15times under cryogenic conditions. Torture TestOne of the nation’s leading actuator manufacturersapplied HI-T-LUBE on critical component parts of a hightemperature ball screw actuator used as a positioningdevice for the variable afterburner exhaust nozzle on theJ-85 jet engine. Typical components of the actuator,which demanded an uncompromising lubricant to operatein a temperature range of –65°F (–54°C) to +840°F

(+449°C), were trunion and gimbal mechanisms, slidingthrust rods, and highly loaded thrust bearings. Althoughre-lubrication at 150-hour intervals was permissible onactual engine tests, more torturous testing proved thatHI-T-LUBE coated parts survived without re-lubricationfor up to 485 hours of test life.VibrationFrom the report on a HI-T-LUBE test of an actuator usedon a new high performance jet engine: “...during jitter-type cycles, the bearings are subjected to extreme abusein that the balls do not complete a revolution over thebearing race and hence tax the lubricant in localizedareas. We have not had any thrust bearing failures whereHI-T-LUBE was used on the actuator applications, norwas there any reported failure of any other component part where HI-T-LUBE was used.”AdherenceThe HI-T-LUBE “synergistic” coating becomes an integralpart of the load-bearing metal surface. It will not chip orrub off. It reduces wear and increases the operating lifeof all metals. From the official report of an aircraft engi-neer: “...bearing life was determined to be a function ofmaterial hardness, tolerances and finish combined withthe degree of positive lubrication offered by HI-T-LUBE.”High VacuumUnlike conventional coatings or lubricants, which generateoutgassing when subjected to high vacuums, HI-T-LUBEdry-film lubricant coated instrument parts have success-fully withstood outgassing problems at 10-7 Torr.Parent Metal SubstratesHI-T-LUBE can be applied to virtually all metals normallyused where components are subject to high compressiveforce: steel, stainless steel, copper, copper alloys, etc. Itmay also be successfully employed on aluminum wherethat metal’s surface will withstand the compressionforces involved in the application.

An Explanation of How HI-T-LUBE's Patented Matrix Construction Works

Engineering Test Data

Malleable, dry-lubricantlayer

Hard, thin, oxide layer

Semi-soft, compressible,metal layer

Initial, hard, interfacemetal layer

Base metal

HI-T-LUBE’s Patented Matrix Construction

Federal and Industrial Specifications Typical Applications For HI-T-LUBE®

Excerpt From The Guinness Book of World Records, WhichRecognizes HI-T-LUBE as the World’s “Slipperiest” Solid!

HI-T-LUBE is currently employed in the manufacture ofspacecraft, aircraft, and missiles, as well as throughoutthe broad spectrum of manufacturing, processing, andpackaging industries.

It has received special recognition from NASA and theNJ Wing of the Air Force Association, and is approvedunder specifications from such companies as Pratt &Whitney, Lockheed Martin, DuPont, GE, RCA, IBM,Boeing, Fisher Controls, Marotta Scientific, Perkin Elmerand Princeton University, to name just a few.

Acme threadAircraft parts of all typesBall jointsBearing surfacesChainsEnginesFurnacesGearsHousingsImpellersNuts, bolts, and screws

OvensPistonsRingsRollers and roller bearingsShaftsSplinesTenter framesThreadsTorque measuring devices...Plus any other sliding

or mating metal parts

“I put five materials togetherand composited them into alubricant. It worked the firsttime,” declared Dr. Charles P.Covino, the founder of GeneralMagnaplate and the inventor ofHI-T-LUBE®.

HI-T-LUBE surface enhancement coating registers thelowest coefficient of static and dynamic friction of anysolid material in the world. HI-T-LUBE is recognized asthe world's "slipperiest" solid by The Guinness Book OfWorld Records.

Dr. Covino invented HI-T-LUBE in theearly 1960’s and soon after he wascontacted by the US Air Force toinvestigate a series of accidents involvingF105s. Covino discovered that the speedbrake pedals were constantly jamming.“The pedals were cooking hot fromexposure to the jet flame, then freezingwhen the exhaust was opened and the airstream hit them. They would goimmediately from super-hot to sub-zero.”The inventor realized that the solution was a new metalalloy that would take the heat, swell up, then go backand compress quickly; his recently invented HI-T-LUBE.

HI-T-LUBE also played a critical role in the space pro-gram of the mid-1960s. NASA was faced with severeproblems. Its missions required on-board equipment tofunction in the vacuum of space, an environment wherethe use of conventional lubricants was impossible. “Theytried everything, including metals like graphite and silver,but everything migrated once it was in a high vacuum.The metals would actually grow whiskers, which wouldthen either jam moving parts or act as conductors andshort out electronic systems,” said Covino.

The problem was solved when Covino layered gold ontop of the HI-T-LUBE alloy he had used on the F105s. “Itwas the only thing that held together and lubricated in a vacuum or in both high heat very cold zones,” saysCovino. HI-T-LUBE was used for the first trip to the moon

and subsequently for trips to Venus and Mars. The MarsProbe had approximately 400 pieces lubricated with thealloy.

Back on earth, Covino’s invention, HI-T-LUBE, as well asother surface enhancement coatings, eliminated theneed for potentially hazardous lubricants, cleaners andchemicals. But even more important to design engineersworldwide is the fact that Magnaplate's coatings prolongthe life of critical metal parts on all types of equipment.Their coatings resist corrosion, friction, and chemicalattack.

All of General Magnaplate's surfaceenhancement coatings also help preservelimited natural resources by allowing theuse of common metals in place of muchmore difficult-to-extract or expensive mate-rials. Friction-reducing coatings, such as HI-T-LUBE, decrease the huge amount ofenergy demanded by the millions of piecesof machinery and equipment needed to keepthe economy flowing. “Certain metals aregoing to be in short supply and we’requickly depleting energies and materials

we can extract from the earth. If lower cost metals, suchas aluminum or magnesium, are coated with HI-T-LUBE,they will be less likely to corrode, bend, wear or fracture,limiting negative effects on the environment.”

Lowest friction Solid The lowest coefficient of static and dynamic friction of any solid is 0.03,for HI-T-LUBE with a bur-nished exterior. The 0.03result was achieved by sliding HI-T-LUBE againstHI-T-LUBE.

800-852-3301 ■ Fax: 908-862-6110E-Mail: info@magnaplate.comWeb Site: www.magnaplate.com ©

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A. HI-T-LUBE is applied to a huge variety of

parts used on NASA spacecraft, such

as the International Space Station (ISS),

to prevent corrosion, abrasive wear, and

galling in the harsh environment and

extreme temperatures of outer space.

B. A gear assembly is treated with two of

Magnaplate’s non-stick “synergistic”

surface enhancements, HI-T-LUBE and

NEDOX®, to prevent wear, sticking,

and galling.

C. All types, shapes, and sizes of gear

assembly components are protected

against chemical attack, wear, and

galling by HI-T-LUBE.

D. Thousands of critical parts on USAF jet

fighters and other aircraft are treated

with HI-T-LUBE to prevent wear caused

by abrasion and corrosion. It also

eliminates malfunctions due to high

heat operating conditions.

E. HI-T-LUBE protects gears and shafts

from wear and galling.

F. HI-T-LUBE coating eliminates wear and

corrosion on various types of gears

and rings.

G. HI-T-LUBE is recommended for use on

all types of gears and gear assemblies

to prevent abrasive wear under

heavy loads at both high and

low temperature extremes.

Examples of HI-T-LUBE® Coatings in Use

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