Ceramic Coating
Services

Thermal spray ceramic coating uses a plasma gun or HVOF torch to heat ceramic powder to molten or semi-molten state and accelerate it onto the substrate surface. The molten particles impact and solidify in a lamellar (layered) structure, creating a dense, well-adhered ceramic deposit without heating the substrate to high temperatures.

A TBC is a ceramic coating system — typically yttria-stabilised zirconia (YSZ) — applied to metallic components in high-temperature environments. TBCs reduce the surface temperature of the metallic substrate by acting as a thermal insulator, extending component service life and enabling higher engine operating temperatures. They are standard on gas turbine combustors and vanes.

Our plasma-sprayed ceramic coatings achieve bond strength of >35 MPa as measured by ASTM C633 pull-off test. YSZ TBC systems over MCrAlY bond coats typically achieve 25–40 MPa. Bond strength certificates are available for aerospace and critical applications.

Yes, but with limitations. Aluminium has a low melting point and the thermal spray process must be carefully managed to avoid substrate overheating. We use controlled spray parameters and cooling to apply ceramic coatings on aluminium. Alumina (Al₂O₃) is the most common ceramic for aluminium substrates.

Yes. Ceramic coatings are routinely finish-ground using diamond wheels. We grind to surface roughness Ra as low as 0.2 μm and dimensional tolerances of ±5 μm on ceramic-coated cylinders and rolls. Post-spray grinding is recommended for all precision applications.

YSZ has very low thermal conductivity (~2.2 W/mK), making it ideal as a thermal barrier coating. It is resistant to thermal shock but not recommended for abrasion. Alumina (Al₂O₃) has higher hardness (1100–1200 HV) and lower porosity, making it better for wear, abrasion, and electrical insulation at moderate temperatures up to ~800°C.