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.