As thermal spraying specialists, our clients always want to know how thermal barrier coatings keep things cool. The science is very simple, but the benefits of thermal barrier coatings are unmissable for countless businesses. To find out how thermal barrier coatings keep things cool, continue reading this blog.
What Are Thermal Barrier Coatings?
Thermal barrier coatings are one example of engineering coatings, which enhance the surface properties of a sprayed component to improve mechanical performance.
Numerous applications across multiple industries require or generate heat while in production. If left unmanaged, this can be a serious threat to operators, and in the most severe cases, lead to loss of life.
In instances where manual operators are not threatened by unmanaged heat, it can still be extremely detrimental to equipment, causing thermal degradation, oxidation, and loss of structural integrity. So, in any case, extreme heat must be managed.
Thermal barrier coatings are powerful insulators. By depositing a thin layer of superalloy metal or ceramic, the underlying substrate is protected from extreme temperatures and thermal cycling.
If you would like to know how thermal barrier coatings keep things cool, you can also check out our blog Everything You Need To Know About Thermal Barrier Coatings.
How Thermal Barrier Coatings Keep Things Cool: The Science Behind TBCs
The primary function of thermal barrier coatings is to offer extreme temperature protection and prevent heat conduction. Aside from this, they also offer corrosion-resistant and highly durable properties.
Friction or vigorous movement in machinery causes a spike in thermal energy. Thermal barrier coatings work effectively to isolate that energy and protect the mechanical components from thermal damage.
The science behind TBCs is surprisingly simple. By creating a thermal gradient, thermal barrier coatings can endure high external temperatures while keeping the underlying substrate significantly cooler.
To achieve excellent results, thermal barrier coatings are usually applied in layers, offering supreme protection. The first layer, a metallic bond coat sprayed directly onto a prepared substrate, adheres strongly and provides corrosion protection. The external topcoat reflects heat, as opposed to absorbing it, limiting conduction. Both layers work effectively in tandem to dissipate and deflect heat.
How Thermal Barrier Coatings Keep Things Cool: Industry Examples
Aerospace
In modern, high-performance aviation gas turbines, temperatures may exceed 2,000° C. To be deemed 'airworthy', aerospace applications must adhere to strict regulatory requirements.
Ensuring components can handle such temperatures is crucial for aerospace applications. In this instance, component failure may lead to loss of life. Thermal barrier coatings help aerospace engineers meet stringent requirements in design.
With TBCs, turbines and engines can reach high temperatures without impacting fuel efficiency and the longevity of component lifespan.
Automotive
According to Turbo Dynamics, the average temperature of exhaust gas at the entry point to a diesel turbo is 800°C. Without the surface technologies offered by thermal barrier coatings, automotives would be inoperable.
Thermal barrier coatings are used in high-performance automotive engines to ensure that exceeding temperatures do not travel to where they are unwelcome. By keeping things cool, TBCs allow for a higher energy output and increased durability in automotive applications.
Energy & Power Generation
For heavy-duty turbines used in energy & power generation, the combustor outlet temperature can reach 1300°C – 1700°C. A lack of thermal management can lead to catastrophic system failures, which will have widespread implications.
Utilising thermal barrier coatings in the energy & power industry will ensure consistent operations over a prolonged period. By maximising thermal efficiency, the need for maintenance downtime, and the inflated costs that come along with that, are reduced.
Benefits Of Thermal Barrier Coatings
- Enhanced Thermal Protection- TBCs work effectively to confide heat to where it is necessary for operational purposes and away from where it is not wanted.
- Improved Operational Efficiency- TBCs allow systems to operate a higher temperature without threat of failure, thereby improving combustion efficiency.
- Extended Component Lifespan- By reducing thermal stress, TBCs work effectively at reducing the risk of oxidation and thermal fatigue
- Corrosion Resistance- Sprayed materials for TBCs have advanced properties that also offer corrosion protection to the underlying substrate.
- Reduced Maintenance Costs & Downtime- As systems are protected from the impact of extreme temperatures, there is a reduced requirement for maintenance intervention.
- Improved System Durability- TBCs allow components to endure constant thermal cycling, which would cause surface damage to unprotected parts.
- Higher Operating Temperatures- Applying TBCs to systems allows them to run at elevated temperatures, maximising performance without jeopardising structural integrity.
- Design Flexibility- The lightweight and thin profile of TBCs means they can be factored into even the most intricate component designs.
How Alphatek's Thermal Barrier Coatings Keep Things Cool
We hope this blog has been useful and you now understand how thermal barrier coatings keep things cool. For the best results, we suggest Alphatek's thermal barrier coatings.
The aim of our thermal barrier coatings is simple: to maximise your profits and keep production running. No matter your industry or the requirements of your application, if managing heat is an issue, you need insight into our extensive range of thermal barrier coatings. Take a look at some of the clients we have worked with previously.
If you would like more information about Alphatek's thermal barrier coatings or are interested in any of our services, please get in touch with us.
