With so many suitable materials and application methods, finding a thermal barrier coating solution for your needs can be challenging. In today’s blog, we will assess your needs and what you might be looking for in a thermal barrier coating. Read on to find out how Alphatek can assist with all your coatings needs!
Understanding Thermal Barrier Coatings
Thermal barrier coatings (TBCs) are a form of surface technology. As stated in the Bodycote glossary, TBCs reduce the rate of heat transfer, allowing a component to work at extreme temperatures.
By projecting a molten material onto a substrate, its surface properties are altered and enhanced. This broadens the scope of equipment usage, without needing to invest in limited, expensive materials.
In a lot of applications, overheating can be fatal for machine operators. While substantial heat may be required or generated in one place, if unmanaged, it can spread to places where it isn’t welcome, causing severe burns.
Confining thermal energy to a specific place while isolating it from other components has allowed engineering teams to operate safely and with flexibility. TBCs have also been known to extend the lifespan of components, by making them less susceptible to extreme heat damage.
Establishing Your Specific Needs For Thermal Management
In automotive applications, the average temperatures of engine compartments are steadily becoming hotter and hotter. To ensure drivability and safety, heat must be managed and diverted away from drivers, as well as other components that don’t possess the same thermal resilience.
It is a persistent challenge for engineers who require extreme heat for functional or production purposes in one area, to ensure it remains enclosed. It can also be difficult to source materials that can withstand such extreme temperatures, without altering their original properties.
When finding a thermal barrier coating solution for your specific needs, questions you must ask yourself are-
- Do you need to isolate heat conduction in an application?
- Do you need to increase the thermal resistance of a component?
- Do you need to improve the component’s thermal fatigue resistance?
- Do you need to prevent oxidisation or corrosion?
Key Factors For Finding A Thermal Barrier Coating Solution For Your Specific Needs
- Operating Temperature
A range of materials, from different metals to ceramics, can be used for thermal barrier coating solutions. Ensuring the material sprayed is compatible with the temperature it will encounter is necessary for a lasting solution.
2. Material Compatibility
Some substrates will have a different bond compatibility with different spray materials. Finding materials that are compatible will lead to a better, more effective adhesion.
3. Environmental Conditions
Exposure to corrosive environments or oxygen will determine what materials are suitable for an application, as some offer better protection than others. Some components must be able to withstand rapid heating and cooling.
4. Mechanical Stress
Wear and impact resistance of components may also impact the thermal barrier coating used, as some spray materials offer greater protection against friction, erosion, and degradation.
5. Coating Thickness
Components required in hard-to-fit places may have limitations on coating thickness. The coating solution must offer optimal protection without adding excess weight or altering component dimensions.
Types Of Thermal Barrier Coating Solutions
Ceramic Coatings
Ceramic coatings are used widely in thermal barrier applications, due to their highly effective insulation properties and ability to withstand high temperatures. Ceramics are also resistant to erosion and corrosion, which is ideal for offering protection in harsh environments.
Metallic Coatings
Metallic coatings provide thermal shock resistance, enhancing a component’s ability to withstand swift temperature changes. They also offer superior adhesion qualities, as well as oxidisation and corrosion resistance.
Composite Coatings
Composite coatings combine the qualities in metallic and ceramic materials, to bring forth a better-performing spray solution. The composition results in enhanced thermal protection and mechanical properties.
Application Methods For Thermal Barrier Coating Solutions
The process is highly customisable, from the sprayed material, substrate, and application method. There are various application methods when it comes to thermal barrier coatings, as specific spray methods are better suited to specific materials.
Flame Spraying
A fuel of combustion and oxygen causes a chemical reaction, which melts the coating material. The molten particles then form a wire that is transferred to the nozzle of a heat gun. Compressed air then projects the particles out of the nozzle. Once they hit a substrate, the particles cool and form a solid coating.
Arc Spraying
Electricity is used to heat the coating material, which is then atomised by compressed air. A spray team is then formed and then applied to a prepared substrate.
Plasma Spraying
A plasma jet is formed by ionising a gas using an electric arc. A powder-form coating material is then injected into the plasma jet, where is melted down and projected onto a substrate.
For more information, read our blog A Guide To Different Metal Spraying Processes.
Finding A Thermal Barrier Coating Solution For Your Specific Needs At Alphatek
Finding a thermal barrier coating solution for your specific needs requires certain expertise.
At Alphatek, we have over 120 years of cumulative experience. We have worked on various applications, in a number of industries.
No matter what your application may be, we are confident in our ability to provide lasting solutions that are excellent value for money. Don’t just take it from us, you can access our certified quality assurance here.
Our team are happy to offer their expert advice, so you find the most compatible thermal barrier coating based on your needs. If you have any questions about our proprietary coatings, you can contact us today.
