Thermal Barrier Coatings — Technology for Diesel Engines

Thermal Barrier Coatings (TBC) are a development of the aerospace industry primarily aimed at hot gas flow paths in turbine engines. TBC consists of zirconia ceramic coatings applied over an (M)CrAlY) These coatings can provide three benefits: (1) a reduction of metal surface operating temperatures, (2) a deterrent to hot gas corrosion, and (3) improved thermal efficiencies.

TBC brings these same benefits to reciprocal diesel engines but coating longevity must be demonstrated, Diesels require thicker deposits and have challenging geometries for the arc-plasma spray (APS) deposition process.

Different approaches to plasma spraying TBC arc required for diesels, especially where peripheral edge effects play a major role. Bondcoats and ceramic top coats arc modified to provide extended life as determined by burner rig tests, using ferrous and aluminum substrates.