
From jet engines to steam turbines, heat is often a necessary component to some of the planet’s largest jobs. But while high temperatures are essential to the proper function of a machine, it can also threaten the most integral parts.
Thankfully, there’s a solution: thermal barrier coatings.
Thermal barrier coatings not only help machinery run more efficiently, they extend the lifespan of your equipment, allowing you to get more done. Let’s take a closer look at this amazing product and see how it can work for you.
What is a Thermal Barrier Coating?
Thermal barrier coatings (TBCs) are a protective layer applied to surfaces to insulate components from extreme heat, improving their performance and lifespan, even under intense operating conditions.
Thermal barrier coatings are a vital technology in many industries—from aerospace to manufacturing.
How Do Thermal Barrier Coatings Work?
Thermal barrier coatings work by providing an insulating layer between high-temperature environments and the underlying material. In turbine applications, TBCs are an advanced solution to extreme conditions and extend the life of engine components.
Here’s a step-by-step explanation of how they function:
Ceramic Topcoat
The top layer of a TBC is typically made from a ceramic material, like yttria-stabilized zirconia (YSZ), which has a high melting point and functions as a thermal insulator. This ceramic layer has low thermal conductivity, which means it slows down heat transfer. This primarily insulates and reflects heat, ensuring the underlying material remains at a lower, more manageable temperature.
Bond Coat
Beneath the ceramic layer is the bond coat. The bond coat typically consists of alloys that improve the adhesion of the ceramic topcoat to the metal substrate, preventing wear under intense operating conditions.
Metal Substrate
The metal substrate is the actual component that needs protection with the TBC. This could be a turbine blade, an engine part, or any other component exposed to high temperatures.
What Happens Without a Thermal Barrier Coating?
Without a thermal barrier coating on an object that needs one, components like turbine engines are exposed to extreme temperatures and thermal stress, causing accelerated wear and tear.
Lack of a thermal barrier coating can result in material degradation, including oxidation and corrosion, which compromise the structural integrity and efficiency of the equipment.
Over time, this lack of protection can cause premature failure, increased maintenance costs, and potentially catastrophic breakdowns.
What Are Thermal Barrier Coatings Used For?
Thermal barrier coatings are used in several high-stress industries:
Steam and Industrial Gas Turbines
In gas and steam turbines, thermal barrier coatings are crucial for protecting turbine blades and other components from the extreme heat generated during operation. By insulating these parts, TBCs allow turbines to operate at higher temperatures, which improves efficiency and power output while reducing the risk of thermal fatigue and oxidation.
This results in longer-lasting components and lower maintenance costs, making TBCs an essential technology in power generation.
Aerospace Applications
In the aerospace industry, TBCs are extensively used on gas turbine engines, jet engines and other high-temperature components.
These coatings protect engine parts from the intense heat and stress encountered during flight, ensuring the reliability and safety of the aircraft.
By allowing engines to run at higher temperatures, TBCs enhance fuel efficiency and performance, contributing to the overall effectiveness and longevity of aerospace components.
Advanced Ceramics Applications
Thermal barrier coatings play a vital role in advanced ceramics by protecting these materials from thermal shock and degradation.
In applications such as heat exchangers, furnaces, and other high-temperature environments, TBCs help manage heat and prevent damage to ceramic components.
This enhances the durability and functionality of advanced ceramics, making them more reliable and efficient in demanding industrial processes.
Metal Shops and Titanium Industries
In metal shops and titanium industries, TBCs are applied to metal parts to shield them from high temperatures, oxidation, and corrosion.
These coatings are particularly important for titanium components, which are used in critical applications due to their strength and lightweight properties.
TBCs help maintain the integrity and performance of metal parts under extreme conditions, extending their service life and reducing the need for frequent replacements.
FAQs About Thermal Barrier Coatings
What materials are used in thermal barrier coatings?
Thermal barrier coatings typically use ceramic materials like yttria-stabilized zirconia (YSZ) in thermal coatings for the topcoat and various alloys for the bond coat.
How are thermal barrier coatings applied?
Common methods for applying TBCs include plasma spraying, electron beam physical vapor deposition (EB-PVD), and chemical vapor deposition (CVD).
Why are thermal barrier coatings important in gas turbines?
TBCs allow gas turbines to operate at higher temperatures, improving efficiency and reducing maintenance costs by protecting components from heat damage.
Can thermal barrier coatings be repaired or replaced?
Yes, thermal barrier coatings can be repaired or reapplied as needed, which helps maintain the performance and longevity of the protected components.
Thermal Barrier Coating Solutions by NTA
At NTA, Niche Tools & Abrasives, we understand the critical role that quality thermal barrier coatings play in your industry. Our full range of products is designed to increase the life of your machinery, allowing you to boost productivity and protect your bottom line.
For example, our diamond products are designed to meet the highest standards of performance and durability. Our diamond grinding discs are heat resistant which means they will last longer in blending, or grinding the TBC. We also offer nano-materials such as graphene products, which provide advanced material properties like enhanced thermal conductivity and durability.
Contact us today to discuss how we can help you achieve your performance goals!