Ceramic Coatings
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
Industries
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.
Applications
- 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
- Paddles
- Impellers
- Doctor blades
- Vanes
- Molds
- Pistons
- Valves
- 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
- Fretting
- Sliding wear
- Erosion
- Abrasion
- Anti-galling
- Hot gases
- Corrosive liquids
- Thermal barriers
- Electrical insulation
- Surface finish benefits
Call (803) 313-9292 or click here to contact MBI for more information.