How Ceramic Coating Use in Automotive and Aviation Industry

Ceramic Coating is are the inorganic materials that are processed and used at high temperatures

Ceramic coatings are normally alumina, alumina-magnesia, chromium, hafnia, silica, silicon carbide, titania, silicon nitride, and zirconia based compositions.

Ceramic Coatings can be used in various industries. It can be derived by devising various technologies such as thermal spray, physical vapour deposition (PVD), chemical vapour deposition (CVD), and others. Other techniques involve dipping, sol-gel, micro-oxidation, packed diffusion, ionic beam surface treatment, and laser assisted techniques

Heat shield
The heat shield is one of the most widely used heat management options available due to its relatively low price and ease to fit. In the past it has usually been custom made from rigid steel; however, flexible aluminium is now the standard.

More recently technology has become available to apply ceramic thermal barrier coatings onto flexible aluminium in order to increase the thermal insulation properties. This same procedure is also used on composite materials, which is often used on high-performance race cars, such as in Formula 1.

Ceramic paintThis fairly low-cost solution can offer minor reductions in heat loss. It is often applied by brushing or spraying from an aerosol onto the exhaust system, followed by curing in the oven to allow the paint to adhere. This is sometimes applied to the internal surfaces of the exhaust, however, this often flakes prematurely due to the inability to clean the surface prior to application. It is usually necessary to reapply every 1–2 years due to it flaking and peeling.

Thermal barrier coatingThese ceramic coatings are highly advanced coatings applied via plasma spray, and as a result, the coating is effectively welded to the surface of the exhaust system. They can offer small performance benefits [1] due to the low thermal conductivity of the ceramic compound. This reduces engine bay temperature and increases exhaust velocity. These coatings protect steel exhaust systems further by protecting from rust.

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Use of Ceramic in AutomotiveThermal barrier ceramic coatings are becoming more common in automotive applications. They are specifically designed to reduce heat loss from engine exhaust system components including exhaust manifolds, turbocharger casings, exhaust headers, downpipes and tailpipes. 

This process is also known as "exhaust heat management". When used under-bonnet, these have the positive effect of reducing engine bay temperatures, therefore reducing the intake air temperature.

Although most ceramic coatings are applied to metallic parts directly related to the engine exhaust system, technological advances now allow thermal barrier coatings to be applied via plasma spray onto composite materials. 

Use of Ceramic in AviationInterest in increasing the efficiency of gas turbine engines for aviation applications has prompted research into higher combustion temperatures. Turbine efficiency is strongly correlated with combustion temperature through the completeness of the combustion reaction. Lower temperature combustion breaks fewer hydrocarbon bonds and ultimately produces less thrust requiring more fuel. Thermal barrier coatings are commonly used to protect nickel-based superalloys from both melting and thermal cycling in aviation turbines. Combined with cool air flow, TBCs increase the allowable gas temperature above that of the superalloy melting point.

To avoid the difficulties associated with the melting point of superalloys, many researchers are investigating ceramic-matrix composites (CMCs) as high-temperature alternatives. Generally, these are made from fiber-reinforced SiC. Rotating parts are especially good candidates for the material change

Future Market of Ceramic CoatingThe global ceramic coatings market is expected to grow at a CAGR of 7.50% from 2015 to 2020 to reach a value of $10.12 Billion. The transportation & automotive industry is one of the major factors responsible for this growth. A large number of new product launches, and expansions in the last five years point towards the strong growth of this market in the near future.

Asia-Pacific dominated the ceramic coatings market in 2014, accounting for over 38% of the market by value and around 43% of the market by consumption. The market by value and consumption for China was the largest in Aisa-Pacific in 2014 and is projected to grow at a CAGR of 8.72% by value from 2015 to 2020 to garner a market size of $1,633.43 Million by 2020 from $984.52 in 2014. RoW region is projected to grow at the fastest CAGR of 9.72% by value and 9.09% of consumption from 2015 to 2020.

Key Player 
Competitive scenarios of the key players in the ceramic coatings market have been discussed in detail. Leading players in this market, including APS Materials Inc., Bodycote PLC, Praxair Surface Technologies Inc., Kurt J. Lesker Co., with their recent developments and other strategic activities are also profiled in the report.