Heat treatment advisory, failure analysis, metallurgical testing, surface treatment consulting, and compliance documentation — from credentialed metallurgists with aerospace, nuclear, and automotive industry experience. Based in Toronto, Ontario. Serving manufacturers across Canada and the US Great Lakes Region.
Microstructure evaluation, hardness mapping, failure analysis, and PMI/XRF — laboratory-grade results you can rely on for compliance, sourcing decisions, and quality control.
Specification-referenced cycle design and processing — hardening, annealing, carburizing, brazing, and on-site hardness evaluation. AMS · AS9100 · CQI-9.
When parts fail — in service, after heat treatment, or at incoming inspection — we find out why, and provide corrective action reports suitable for audits.
Process guidance for surface engineering operations — coating inspection, decarburization analysis, atmosphere control review, and pre/post-treatment evaluation.
Audit-ready documentation for NADCAP AC7102 readiness, CQI-9, AS9100 Rev D, and AMS specifications — built to pass your customer's requirements.
Heat treatment fundamentals, CQI-9 awareness, NADCAP readiness, and custom on-site workshops for operators, quality teams, and supervisors.
Every new engagement starts with a complimentary 30-minute technical consultation. Bring your distortion problem, failed hardness result, audit finding, or supplier dispute — and you'll leave with a clear picture of the root cause and a defined path forward. No commitment. No sales pitch. Just engineering.
Laboratory-grade metallurgical evaluation, hardness mapping, failure analysis, and material verification — backed by 15+ years of hands-on experience across aerospace, nuclear, and automotive industries.
Specification-referenced testing and evaluation for compliance, failure investigation, incoming material verification, and supplier quality documentation.
Sample preparation, etching, and optical microscopy — grain size, phase distribution, carbide morphology, case depth, decarburization, and inclusion assessment.
Macro and micro hardness testing with full traverse data — surface to core — for case depth confirmation, heat treat verification, and incoming material inspection.
Fractographic and microstructural investigation of in-service failures, heat treat non-conformances, and supplier quality escapes — formatted for audit submission and SCAR issuance.
On-site XRF field service for incoming material inspection, mixed alloy sorting, and pre-weld verification. Certificate of Conformance per lot.
We provide consulting advisory on aluminum and copper remelting, purification, and alloy process design — drawing on direct foundry and materials experience. Small-batch remelting and purification for prototyping, R&D, and specialty casting customers.
Consulting on melt practice, alloy selection, flux treatment, degassing parameters, and casting defect analysis for aluminum and copper operations.
From raw scrap to high-purity alloy — flux treatment, degassing, filtration, and refining to remove tramp elements and bring metal to specification grade.
Metallographic and compositional investigation of casting defects — porosity, shrinkage, cold shuts, inclusions, and hot tears — with corrective process recommendations.
Every batch is chemically verified by spectrographic analysis with a Certificate of Conformance issued per heat — suitable for customer quality records and ASTM / AMS grade confirmation.
Actual investigations we have conducted — every finding backed by metallographic evidence, hardness data, and written corrective action documentation.
Manufacturing · Failure Analysis · Surface Engineering
Low carbon steel components from an overseas supplier began failing in service — brittle fracture and premature fatigue inconsistent with the grade. No metallurgical data existed from the supplier.
Finding: Components were supplied without any surface hardening treatment. We developed a controlled nitrocarburizing cycle matched to the steel chemistry and service requirements.
Outcome: Compound layer depth confirmed within specification. Full report provided objective evidence of the supplier's failure — supporting the client's commercial claim.
Heavy Industry · Forging · Inclusion Analysis · Supplier Quality
Repeated fractures of large-diameter forged steel bars in a high-load structural application — consistent failure mode across the production lot, indicating a systemic issue.
Finding: Two independent non-conformances: elongated oxide/silicate inclusions exceeding the cleanliness standard, and coarse prior austenite grain structure from excessive forging temperature.
Outcome: Laboratory-verified report supported the client's SCAR. Foundry revised deoxidation practice and forging parameters.
Commercial Heat Treatment · Process Optimisation · Quality Recovery
Ontario machine shop: 4140 parts requiring 38–42 HRC returning at 28–34 HRC at centre. Supplier had already been changed once without resolution.
Finding: Insufficient austenitising soak time for section size + inadequate quench severity. Revised to polymer quenchant at controlled concentration with extended soak time.
Outcome: Parts consistently achieved 39–42 HRC through the full section. Hardness variation reduced from 6 HRC to under 2 HRC points.
Heat Treatment Operations · Process Development · Cost Reduction
Commercial heat treater needed to reduce carburizing cycle time for AISI 8620 without compromising effective case depth — energy costs and throughput were the drivers.
Approach: Structured boost/diffusion programme across four target case depths (0.04″–0.10″). ECD verified by hardness traverse per ASTM B934 after each iteration.
Outcome: 21% total cycle time reduction. At 0.10″ depth, 5 hours eliminated per cycle — meaningful reduction in energy and direct labour cost per production week.
Microstructure examination for grain structure, porosity, inclusion content, and heat treatment response in 1xxx–7xxx series alloys.
HB, HV, and Leeb hardness testing for incoming verification, heat treatment qualification, and age hardening response per AMS 2770.
Solution treat, quench, and artificial aging cycle design per AMS 2770 for 2xxx, 6xxx, and 7xxx series. Quench delay management and distortion guidance.
Consulting on melt practice, flux treatment, and degassing for aluminum remelting. Small-batch purification and alloy certification for R&D and prototype quantities.
Every engagement starts with a complimentary 30-minute technical consultation. No commitment — just a direct conversation with a credentialed metallurgist.
Full heat treatment processing, cycle recommendations; hardening, stress relief, brazing, annealing, carburizing, carbonitriding, on-site hardness evaluation, and specification-grade advisory. NADCAP · AMS · AS9100 Rev D · CQI-9.
Full, process, and subcritical annealing for steels, aluminum, copper, and brass to restore ductility and relieve residual stresses post-machining or forming.
Through-hardening with oil, water, polymer, or air quench media. Controlled atmosphere furnaces prevent decarburization.
Precise tempering for hardened steels and artificial aging (T6, T73, T76) for aluminum alloys per AMS 2750 pyrometry requirements.
Solution treating of aluminum, copper, and nickel alloys with rapid quench to maximize solid-solution hardening prior to precipitation aging.
Grain refinement via normalizing, plus carburizing and nitriding for hard, wear-resistant surfaces on steel components.
Portable hardness testing performed directly at your facility on finished or in-process components. Testing method (Rockwell, Brinell, Vickers, Leeb/Equotip) selected based on part geometry, section thickness, surface condition, and access constraints. Results documented with location maps and certification report.
Our metallurgists provide specification-backed recommendations aligned to your alloy, geometry, and applicable standard.
We are not NADCAP certified — we help you get there. AC7102 checklist gap assessment, audit preparation, process documentation review, and corrective action support — so you are ready before the auditor walks in.
We map your alloy and application to the correct AMS specification with documented cycle parameters.
Process Table identification, record requirements, and CQI-9 4th Edition audit preparation for Tier 1 & 2 suppliers.
Process FMEA, control plan development, First Article documentation, and risk-based process controls for AS9100 facilities.
We provide brazing cycle design and process advisory for gold, nickel, copper, and silver filler metals across furnace, torch, and induction brazing applications. Recommendations are referenced to AWS C3.3 and applicable AMS specifications, with documentation suitable for NADCAP and AS9100 programs.
Gold brazing alloys offer exceptional corrosion resistance, high-temperature capability, and excellent wettability on nickel, stainless, and cobalt superalloys. Used predominantly in aerospace, medical device, and high-vacuum applications where joint cleanliness and oxidation resistance are critical.
Cycle Advisory: Ramp to brazing temperature at 5–10°C/min above 800°C to prevent thermal shock on complex assemblies. Hold at brazing temperature for 5–15 minutes depending on joint mass. Cool under vacuum or protective atmosphere to below 500°C before exposure to air. Post-braze aging may be required to restore base metal properties per AMS 2675.
Applications: Turbine blade repair, honeycomb core brazing, medical implants, high-vacuum electronic assemblies.
Nickel brazing alloys provide excellent oxidation and corrosion resistance at elevated temperatures. Widely used in aerospace turbine components, heat exchangers, and stainless steel assemblies requiring service above 800°C. Typically processed in vacuum or dry hydrogen atmosphere furnaces.
Cycle Advisory: Pre-braze cleaning is critical — degrease and abrasive clean all faying surfaces. Ramp at controlled rate to 980°C, hold 15 min for thermal equalization, ramp to brazing temperature, hold 5–10 min. Rapid cool below 980°C to minimize boron diffusion into base metal grain boundaries. Diffusion anneal (1095°C / 4 hr) may be required per AWS C3.3 to homogenize joint and reduce brittle phases.
Applications: Turbine engine components, aerospace heat exchangers, stainless honeycomb structures, NADCAP furnace brazing programs.
Copper brazing alloys provide high conductivity, good ductility, and excellent joint strength on steel, stainless, and nickel alloys. Pure copper brazing (BCu) is performed in reducing atmosphere or vacuum furnaces at high temperature. Copper-phosphorus alloys (BCuP) are self-fluxing on copper and copper alloys and are widely used in HVAC, refrigeration, and electrical assemblies.
Cycle Advisory (BCu furnace brazing): Surface preparation is essential — any oxides will prevent copper flow. Use a reducing atmosphere (H₂ or dissociated ammonia) or vacuum at 10⁻⁴ torr minimum. Ramp to 1093°C, hold for uniformity, ramp to brazing temperature, hold 2–5 min only — copper is mobile and will over-flow if held too long. Cool to below 700°C before atmosphere change. BCuP alloys: torch or induction; self-fluxing on copper only — do not use on ferrous metals.
Applications: Steel and stainless assemblies, electrical bus connections, hydraulic fittings, diamond tool brazing, heat exchangers.
Silver brazing alloys offer the most versatile performance range — joining copper, brass, bronze, steel, stainless, and nickel alloys at moderate temperatures. The BAg family spans from low-temperature (560°C) to high-temperature (900°C) alloys and can be applied via torch, induction, furnace, or resistance brazing with flux or controlled atmosphere.
Cycle Advisory: Select alloy based on base metal, service temperature, and cadmium-free requirements (BAg-7 or BAg-24 for food-grade and medical). Apply flux immediately after cleaning — do not allow oxidation before heating. Heat base metal, not the filler. Apply filler at brazing temperature — it should flow immediately. Post-braze flux removal is mandatory; use hot water quench or mechanical removal. For furnace brazing: use a reducing atmosphere to eliminate flux entirely.
Applications: HVAC assemblies, copper-brass plumbing, carbide tool brazing, stainless medical devices, food processing equipment, electrical contacts.
NADCAP and CQI-9 approved shops must perform Temperature Uniformity Surveys (TUS) and System Accuracy Tests (SAT) on a fixed schedule. We provide advisory and documentation support to help your team qualify your furnaces to AMS 2750 requirements — preparing records, reviewing procedures, and ensuring your documentation is audit-ready.
We help you prepare for Temperature Uniformity Surveys — reviewing your furnace class requirements, thermocouple placement, load conditions, and documentation against AMS 2750 Class 1–6 requirements.
We advise on System Accuracy Test procedures, thermocouple type requirements, and help you prepare documentation to satisfy AMS 2750 table requirements for your instrumentation setup.
Complete AMS 2750 pyrometry record packages — TUS maps, SAT logs, calibration certificates, and furnace qualification history in audit-ready format.
We develop a complete, specification-referenced heat treat or brazing recipe for your alloy and geometry — ready to hand to your furnace operator or include in your process documentation.
Share your alloy, part geometry, process type, and furnace class — our engineers will develop the right cycle and documentation.
Failure analysis & heat treat improvement, XRF/PMI field service, furnace qualification advisory, and NADCAP readiness support — we help you prepare, not just assess.
When a part fails after heat treatment — wrong hardness, quench cracking, distortion, decarburization, or unexpected microstructure — we investigate the root cause, identify contributing process factors, and provide concrete recommendations to improve your heat treatment operation and prevent recurrence. Our focus is not just finding what went wrong, but fixing it.
Investigation of parts failing to meet hardness requirements — too soft, too hard, or non-uniform. Root cause analysis covering cycle temperature, soak time, quench rate, thermocouple accuracy, furnace loading, and atmosphere. Followed by process improvement recommendations.
Fractographic and microstructural investigation of cracking occurring during or after quenching. We identify whether the cause is quench severity, section geometry, steel hardenability, surface condition, or pre-existing defects — and recommend cycle or process changes to eliminate the issue.
Analysis of heat treatment distortion root causes — temperature gradient, non-uniform support, quench direction, residual stress from prior operations, or improper racking. We provide specific distortion mitigation recommendations including racking strategy, quench media modification, and pre-heat treatment stress relief cycles.
Identification of decarburization depth, internal oxidation, or surface contamination resulting from atmosphere control issues. Recommendations cover atmosphere composition, dew point control, furnace integrity, and cycle modification to restore surface carbon and mechanical properties.
Assessment of heat-treated microstructure against specification — grain size, phase distribution, retained austenite, and carbide morphology. Where microstructure is outside specification, we recommend corrective cycle adjustments to achieve the target microstructural condition.
Analysis of brazed joint failures including incomplete fill, void formation, base metal erosion, or joint embrittlement. Root cause investigation covering filler alloy selection, joint clearance, temperature control, atmosphere, and flux use — with process improvement recommendations.
We bring the XRF analyzer to your facility. Ideal for incoming material inspection, mixed material sorting, pre-weld verification, and AS9100 / NADCAP incoming inspection requirements.
Targeted workshops for shop floor operators, quality engineers, and compliance managers — delivered on-site or virtually across Ontario.
Half-day workshop covering the metallurgy behind annealing, hardening, tempering, and aging — why the cycles work, what happens in the microstructure, and how to recognize and avoid common failures.
Audience: Operators, technicians, quality staff
Full-day workshop on CQI-9 4th Edition requirements — Process Table selection, record-keeping, equipment calibration, and how to pass your next automotive customer audit.
Audience: Quality managers, heat treat supervisors
Full-day intensive on NADCAP AC7102 requirements. We guide you through the checklist, review your process documentation and operations, identify gaps, and develop a corrective action plan before your audit. Includes mock audit walkthrough and written gap assessment report.
Audience: Quality managers, NADCAP focal points, process engineers
Half-day workshop on how to identify, investigate, and document heat treatment failures — wrong hardness, quench cracking, distortion, decarburization — and develop corrective actions that satisfy AS9100 and customer requirements.
Audience: Quality engineers, process engineers
Half-day workshop covering brazing filler metal selection, joint design, atmosphere and flux requirements, and quality inspection criteria for gold, nickel, copper, and silver brazed assemblies. Referenced to AWS C3.3 and AMS 2675.
Audience: Brazing operators, quality inspectors, engineers
We build a custom training day around your specific processes, alloys, standards, and upcoming audits. Includes pre-training gap assessment, tailored materials, and a written action plan.
Audience: Any — fully customized to your operation
Every engagement starts with a complimentary 30-minute consultation. Bring your problem — distortion, failed hardness, audit finding — and leave with a clear path forward.
Full hardness converter, quench media selector, and AMS spec quick-reference. Built for metallurgists, quality engineers, and shop supervisors.
Convert between HRC, HRA, HRB, HB (Brinell), HV (Vickers), 15N, 30N, UTS (ksi), and UTS (MPa). Based on ASTM E140 conversion tables.
Enter a known hardness value — all other scales are calculated automatically (ASTM E140).
⚠️ Approximate conversions for steel only — refer to ASTM E140 for precise engineering values. Not valid for aluminum, copper, cast iron, or non-ferrous metals without separate tables. For values outside the HRC 20–68 range, conversion accuracy decreases significantly.
Select your alloy type and section thickness for a starting quench media recommendation. Always verify against the applicable AMS/ASTM specification before processing.
Select alloy family and section thickness for a starting recommendation.
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⚠️ Advisory only — always verify against applicable AMS/ASTM specification, customer requirements, and part geometry before processing.
Estimate effective and total case depth for gas carburizing based on the Harris equation — a widely used empirical model for carbon diffusion in steel. Enter your process temperature, soak time, and alloy type for an engineering estimate. Always validate with hardness traverses and microstructural examination.
Based on the Harris empirical equation for gas carburizing of steel. Results are approximations — verify with actual hardness traverses per AMS 2759/7 or customer specification.
Effective Case Depth (ECD) is the depth from the surface to the point where hardness falls to approximately 550 HV (~52 HRC) — this is the engineering specification dimension per AMS 2759/7. Total Case Depth (TCD) extends to the point where carbon content approaches the core composition, typically ~1.4× the effective case. Actual depth depends on carbon potential, atmosphere control, quench rate, and steel chemistry. These estimates assume a carbon potential of ~0.8–0.9% C and a well-controlled endothermic atmosphere. Always verify with a hardness traverse on a representative cross-section.
⚠️ Engineering estimate only (Harris equation). Not a substitute for specification-referenced cycle design or metallographic verification. Contact our team for a full carburizing cycle design report.
Quick reference for the most commonly used AMS specifications in heat treatment and brazing.
| AMS Spec | Title | Applies To | Key Requirement |
|---|
These tools give you a starting point. For a specification-referenced, audit-ready recipe for your specific part and alloy, our metallurgists provide full cycle design reports from $350. View Cycle Design Pricing →
NADCAP, AMS, AS9100 Rev D, CQI-9 — documentation built to pass your customer audits the first time.
We are not NADCAP certified — we help heat treat operations prepare for NADCAP audits. Gap assessments, documentation preparation, mock audit walkthroughs, and corrective action support.
Full coverage of relevant AMS specs for heat treatment, brazing, and materials.
Heat treatment and brazing process integration for AS9100 Rev D certified and certifying facilities.
Automotive supply chain compliance advisory. Process table selection, records, and audit preparation.
Our metallurgists identify the right standards and build the documentation to match.
We serve manufacturers who need fast, reliable, specification-referenced metallurgical support — without the overhead of an in-house lab. Serving local clients and North America.
50 kg minimum — ideal for jobbing foundries casting aluminum, copper, and brass in small lots. No high minimum order barriers, full material certs every heat.
You process other people's parts. When something goes wrong — wrong hardness, quench cracking, distortion, customer complaint — you need a metallurgist in your corner fast.
Material verification, heat treatment advisory, PMI field service, and scrap recovery for machine shops and contract manufacturers.
You understand NADCAP, AS9100 Rev D, and prime customer surveillance. Every process deviation needs a documented root cause and a corrective action that satisfies the auditor.
Material science advisory and heat treatment consultation for nuclear-grade components and high-integrity applications requiring rigorous documentation and traceability.
CQI-9 compliant heat treatment and PPAP-supporting material certifications for Tier 1 and Tier 2 automotive facilities.
Copper busbars, aluminum conductors, and specialty alloy components for power generation and renewable energy applications.
Pilot runs from 50 kg for materials scientists and developers needing custom alloy compositions or heat treat trials with full characterization.
Tell us about your operation and we will put together a tailored service proposal.
Every inquiry at MetAlloy Solutions is reviewed directly by a credentialed metallurgist. Tell us your alloy, your standard, and your problem — we respond within one business day with a direct, technical answer and a clear path forward.
Every new engagement starts with a complimentary 30-minute technical consultation. Bring your heat treat problem, audit finding, part failure, or quality challenge — and you'll leave with a clear picture of the root cause and a defined path forward. No commitment. No sales pitch. Just engineering.
📍 Based in Toronto, Ontario, Canada · Serving clients across Ontario and the US Great Lakes Region · Field services available on-site · Remote advisory across North America
Your inquiry goes directly to info@metalloysolutions.com — you will hear from the engineer who will do the work.
Built on the Shop Floor. Trusted in the Lab. Delivered to Your Standard.
MetAlloy Solutions was founded by engineers who spent years working inside commercial heat treatment facilities, aerospace quality systems, and materials research environments — learning firsthand what goes wrong when process discipline breaks down and what it takes to get it right.
Our team holds graduate-level credentials in Mechanical and Materials Engineering, with hands-on experience spanning aerospace heat treatment under NADCAP and AS9100 Rev D, nuclear industry material qualification, automotive Tier 1 & 2 supply chain compliance under CQI-9 and PPAP, vacuum and atmosphere furnace operations, metallographic evaluation, failure investigation, and non-destructive evaluation.
We have managed furnace qualification programs, developed heat treatment cycles from scratch for new product introductions, led root-cause investigations on customer escapes, and supported quality teams through prime-customer audits in aerospace and automotive sectors. We have written corrective action reports that satisfied both internal quality systems and external auditors.
We also hold a Project Management Professional (PMP) designation — bringing structured thinking to every engagement: clear scope, defined deliverables, on-time reporting, and transparent communication throughout. Every inquiry receives a direct response from the metallurgist who will do the work — not a salesperson, not a coordinator.
Direct experience working inside NADCAP-accredited heat treatment facilities. We know what the auditor looks for — because we have prepared the documentation, run the gap assessments, and supported quality teams through prime-contractor surveillance.
Material qualification, traceability documentation, and compliance at the highest standard — nuclear industry experience in heat treatment and materials applications where process discipline is non-negotiable.
CQI-9 4th Edition process table advisory, PPAP supporting documentation, and heat treatment process compliance for automotive supply chain customers. We understand the pressure of customer audits and delivery schedules.
Non-Destructive Evaluation certification gives us a complete picture of material and process integrity that most metallurgical consultants cannot offer — connecting surface and subsurface findings to heat treatment root causes.
Quality control, quality assurance, and internal auditing experience across aerospace and industrial sectors. We build corrective action reports and audit-ready documentation because we have been on both sides of the audit table.
Every engagement is scoped clearly, delivered on time, and communicated transparently. You will always know what we are doing, why, and when you will have your deliverable.
"When you work with MetAlloy Solutions, you work directly with the metallurgist. No account managers. No handoffs. Just the engineer who reads your microstructure, writes your report, and stands behind every recommendation."