Thermal Spray Coatings for Thermal Barrier Applications
With a rich history extending over a century, Metallisation Ltd stands as an exclusive UK manufacturer and global supplier of cutting-edge thermal and metal spray equipment - designed for the application of thermal barrier coatings.
What is a Thermal Barrier Coating?
Thermal Barrier Coatings (or TBCs) are protective coatings which are applied to the surfaces of components exposed to high temperatures, such as gas turbine engine parts, exhaust systems and certain industrial machinery.
In practice, it means your components stay cooler, even when operating in very high-temperatures.
Thermal barrier coatings are typically composed of a multi-layered composition. The first layer, called the bond coat, is made of materials such as nickel or cobalt alloys. It sticks to the surface and protects against rust and corrosion. Positioned above the bond coat is a ceramic layer, often constructed using materials such as yttria-stabilised zirconia (YSZ). This ceramic layer serves as the primary insulating barrier.
The coating acts as a shield, insulating components from any intense heat which is generated.
Top 5 Benefits
High Temperature Resistance
Thermal barrier coatings are built to operate at temperatures far beyond what standard materials can handle, making them suitable for extreme heat environments.
Improved Durability
TBCs reduce heat transfer to the base material, lowering operating temperatures and helping to limit wear caused by prolonged heat exposure.
Thermal Expansion Management
The coating helps manage differences in expansion between materials, reducing the risk of cracking or damage during repeated heating and cooling cycles.
Improved Fuel Efficiency
In applications such as turbine blades, TBCs contribute to increased fuel efficiency by optimising combustion processes and reducing heat loss.
Oxidation and Corrosion Protection
TBCs also act as a protective layer, shielding the underlying material from oxidation and corrosion, which can occur at high temperatures in harsh environments.
Thermal Barrier Applications
Thermal barrier coatings are essential in various industries, including aerospace, energy generation, and automotive sectors.
Aerospace
Thermal barrier coatings are used on aircraft engine components to help minimise heat transfer and prevent thermal stress. These coatings help maintain the structural integrity of turbine blades, ensuring they can withstand the rigours of frequent and extreme temperature fluctuations experienced during flight.
Power Generation
Gas and steam turbines, commonly used in power plants, operate at extremely high temperatures – sometimes reaching up to a thousand degrees during operation. The application of thermal barrier coatings on turbine blades serves as a protective layer, shielding them from the intense heat generated during combustion.
Automotive
Thermal barrier coatings are designed to mitigate the impact of high temperatures on critical vehicle parts. Cylinder heads, pistons, and exhaust systems are often coated with thermal barriers to manage high temperatures generated during combustion. Not only does this enhance engine performance but it also contributes to reduced emissions, increased fuel efficiency and reliability.
Additionally, TBCs are useful in diesel engines, turbochargers, and other areas where heat management is crucial.
What Equipment is Used to Apply Thermal Barrier Coatings?
Thermal Barrier Coatings can be applied with our MK74 Powder Pistol. This handheld spray gun delivers the powder through a small gravity fed hopper, mounted on the gun itself or through a separate powder feeder (2007MF-PF). Fully automated versions of the MK74 are also available.
For extreme performance applications, thermal barrier coatings can also be applied by using plasma spraying equipment, producing coatings that are denser and with higher bond strengths than with powder flame spray.
Application Data Sheets
Case Studies
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Frequently Asked Questions
What are thermal barrier coatings used for?
Thermal barrier coatings are commonly used on turbines, exhaust components, boilers, industrial equipment and other parts exposed to high heat.
How thick are thermal barrier coatings?
Typically between 100-500 microns, depending on the application. Thickness is chosen based on heat exposure, component type and required level of thermal protection.
Can coatings be repaired or reapplied?
Yes. Worn or damaged coatings can often be removed and reapplied, restoring the component’s thermal protection without needing full replacement.
How do I know if my business needs thermal barrier coatings?
Does your equipment suffer from heat damage, frequent maintenance, premature wear or high operating temperatures? If so, thermal barrier coatings should be an option worth reviewing.
Can thermal barrier coatings withstand extreme temperatures?
Yes. Thermal barrier coatings are designed to withstand temperatures exceeding 1,000°C.