At MBI we apply ceramic coatings by sophisticated Plasma spray systems.
Our ceramic coatings can transform an ordinary metal into a high-performance surface. When applied by high energy Plasma, The coatings are dense, wear, corrosion & heat resistant, inert to acids, alkali and solvents. They improve the properties of any surface they're applied onto. Because of our higher energy application method our coatings have higher particle-to-particle cohesive bonding which translates into higher quality coatings.
Benefits of ceramic coatings
- High hardness and durability
- Dense and pore free (sealed)
- Thermo-chemical bond strength
- Anti galling
- Electrical resistivity
- Thermal barrier coatings (TBC)
- Resistance to thermal shock
Type of ceramic coatings
Some of the most popular plasma sprayed ceramic coatings include:
- Alumina-Titania based ceramics for wear, corrosion and variable texture surfacing.
- Chrome-oxide ceramic coatings are extremely durable, ideal for seal surfaces.
- Zirconia based ceramic are un-matched as thermal barrier and heat-shield coatings.
There is a variety of ceramic materials that can be applied depending upon the requirements of each application, the chart below lists a few:
|Ceramic type||Hardness||As-sprayed Ra||Ground Finish||Resistance to||Major use example|
|Chrome oxide||70 Rc||130 Ra||1 Ra (lapped)||Abrasive grains wear||Seal surfaces|
|Alumina oxide||52 Rc||150 Ra||>10 Ra||Wear, heat , electrical||Crimper wheels|
|Titanium dioxide||55 Rc||200 Ra||5 Ra||Abrasive grains||Mixer parts|
|Alumina-Titania||68 Rc||110 Ra||1 Ra (lapped)||Fretting, cavitation||Textile parts|
|Zirconium oxide||30 Rc||250 Ra||N/A||Thermal barrier||Molten metal contact|
|Magnesium zir.||31 Rc||300 Ra||N/A||High temperatures||Ingot molds & troughs|
Most applications require thin layers .003-.005” with polished finish anywhere from 20 to 400 Ra.
However, when thicker layers are desired grinding and/or lapping may be required such as on finished roll surfaces and in the packing and seal areas
Textile- Yarn, thread and fabric contact areas requiring extreme wear resistance and specific finishes for ideal low friction. Rolls, heater plates, guide areas, etc.
Pumps- Any pump component exposed to wear, petrochemicals, acids, sea water and chlorines last much longer when coated by ceramics.
Steel and metal- Ceramic coatings are widely used for combating wear and corrosion also, for the protection of components that are exposed to molten metals.
Oil, Gas & Power- Various ceramic coatings are specified on various component surfaces to make parts last longer and minimize down-time caused by corrosion and wear especially on valve and pump equipment.
Plastics & polymers- Ceramic coating specifically designed to prolong the life of components like screws, guides, nozzles, turrets and extruder surfaces.
Automotive- Ceramic coatings are extensively used on automotive parts such as diesel engine pistons, valves, cylinders and headers.
- Rolls & Rollers resurfacing
- Guide surfaces
- Furnace fixtures
- Textile, thread and fiber parts
- Mechanical seal areas (sleeves, journals, etc.)
- Protective coating on calendar and corrugating rolls
- Doctor blades
- Wear rings
- ...Plus much more!
Seal surface being plasma ceramic coated.
Wear plate coated with Alumina- titania ceramic (sliding wear).
Best situations to use ceramic coatings
- Sliding wear
- Hot gases
- Corrosive liquids
- Thermal barriers
- Electrical insulation
- Surface finish benefits
Call (803) 313-9292 or click here to contact MBI for more information.