The Fused Armor formulations and processes are, of course, proprietary.  However, certain basics will be useful.  Fused Armor is an entirely new, patented material.  It exhibits a never seen before combination of physical properties and performance characteristics.  In addition, Fused Armor formulations are water based slurries comprised of non-toxic, environmentally friendly inorganic materials.  In fact, the entire product life cycle, from the application processes through recycling, is non-toxic and environmentally friendly.

Fused Armor's primary attribute is always corrosion protection, regardless of what secondary performance factors are engineered into the cladding, and virtually all corrosion involves oxidation.  Fused Armor forms an impervious barrier to oxidation because it is non-porous and is actually fused into the metal substrate that is being protected.  Additionally, the Fused Armor cladding itself is also impervious to oxidation.  Therefore, oxidation can gain no foothold to even begin the destructive corrosive process.

The Fused Armor material may be applied to the metal substrate by either spraying or dipping.  Once the Fused Armor material is applied to the metal substrate, it is heated so that the material actually fuses into the surface of the substrate.  The heating method can be either via furnace or induction (which utilizes a proprietary application process for use on large flat surfaces such as ship hulls or continuous surfaces such as pipelines).

As a rule, the Fused Armor application will be single layer.  Generally, these claddings are relatively thin, usually 5 to 10 mils (thousandths of an inch) thick.  However, even at such relatively thin applications, Fused Armor dramatically outperforms other coatings which involve multiple applications and are generally 15 to 40+ mils in thickness.


Literally hundreds of individual tests have been successfully performed on Fused Armor formulations and processes -- the Fused Armor system.  These tests comprise an irrefutable body of evidence supporting the superiority of Fused Armor over all comparable existing products and processes.

Fused Armor has outperformed popular epoxies by 600% in abrasion testing.  It has shown electrical resistance beyond the limits of many normal test machines.  Underlying substrates have been deformed far beyond the point at which other coatings fail yet Fused Armor has remained intact and undamaged.  Fused Armor has withstood temperatures ranging from -321°F or -196°C (liquid nitrogen -- close to absolute zero) to over 1650°F or 899°C (today's hottest exhaust manifolds).  Thin applications of Fused Armor have shown thermal insulation properties that can only be duplicated by multiple layers of woven fiberglass insulation blankets.

Fused Armor can withstand hours in boiling sulfuric acid without damage.  It can provide an impenetrable barrier between steel substrates and gases, including hydrogen.  Fused Armor not only protects, it actually increases the strength and performance of the steels it is protecting.  Certain tests and theoretical work by international engineers also suggest additional properties of interest to the Defense and Nuclear Power industries.


The Company's current technology is covered by two patents issued in 2009 (US Patent Numbers 7,547,651 and 7,622,196).  These patents were originally assigned to Fused Armor's founding company, Applied Technology Laboratories, LLC, and have been subsequently reassigned to Fused Armor, Inc.  The Company has also developed considerable additional product and process technology which is under consideration for further patent filings including formulations which can be fused at lower temperatures to prevent possible weakening of certain steels;  an entirely new and more versatile process for fusing Fused Armor into the metal substrates it protects;  and, a new formula for fusing Fused Armor into aluminum and aluminum-based alloys.



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