Thermal barrier coatings (TBCs) are advanced materials applied to surfaces that are exposed to high temperatures. They are designed to provide insulation and protect the underlying substrate from the extreme heat. TBCs typically consist of a ceramic layer, such as zirconia, which has low thermal conductivity. This layer acts as a barrier, reducing the transfer of heat to and from the substrate.
TBCs are commonly used in aerospace applications, such as turbine blades and engine components, as well as in industrial gas turbines and automotive engines, where they help improve efficiency and extend the lifespan of the components.
Another common application of TBCs (Thermal Barrier Coatings) is for sealing building envelopes. Building envelopes refer to the outer layer of a building that separates the interior from the exterior environment. TBCs can be applied to the building envelope to provide insulation and improve energy efficiency by reducing heat transfer. By effectively sealing the building envelope, TBCs help to maintain a comfortable indoor temperature, reduce energy consumption, and enhance the overall sustainability of the building.
ThermaCote produces a ceramic-based TBC designed for building envelopes. It greatly reduces energy transfer, making the heating and cooling of residential and commercial building more efficient. Read on to learn about ThermaCote, other ceramic-based, and metallic-based TBCs and their applications.
Types of Ceramic-based TBCs
1. ThermaCote
ThermaCote is a ceramic-based thermal barrier coating that is applied to the surface of any building or application. This type of TBC is made up of hollow, microsized ceramic particles that are suspended in a binder. ThermaCote reflects heat away from the substrate material and can be used on steel, cast iron, aluminum, stainless steel and other materials in residential and commercial applications. It is available in several different color and is a single-stage thermal coating that you can spray onto your application.
2. Yttria-Stabilized Zirconia (YSZ)
YSZ is one of the most commonly used types of ceramic-based Thermal Barrier Coatings (TBCs). It is composed of zirconia (ZrO2) with a small amount of yttria (Y2O3) added to stabilize the crystal structure. YSZ TBCs offer excellent thermal insulation properties, high melting point, and good resistance to thermal cycling.
3. Gadolinium Zirconate (GZO)
GZO is another popular ceramic-based TBC that is known for its high thermal stability and low thermal conductivity. It is composed of zirconia doped with gadolinium oxide (Gd2O3). GZO TBCs provide good thermal barrier performance and are often used in high-temperature applications.
4. Lanthanum Zirconate (LZO)
LZO-based TBCs are known for their excellent thermal stability and low thermal conductivity. These coatings are composed of zirconia doped with lanthanum oxide (La2O3). LZO TBCs offer improved resistance to thermal cycling and are commonly used in gas turbine engines.
5. Yttria-Calcia-Zirconia (YCZ)
YCZ TBCs are a combination of zirconia doped with yttria and calcia (CaO). These coatings offer enhanced thermal stability and reduced thermal conductivity compared to YSZ TBCs. YCZ TBCs are often used in high-temperature applications where superior insulation properties are required.
6. Magnesium Zirconate (MZO)
MZO-based TBCs are composed of zirconia doped with magnesium oxide (MgO). These coatings offer good thermal stability and low thermal conductivity. MZO TBCs are commonly used in aerospace and gas turbine applications.
7. Hafnium Oxide (HfO2)
Hafnium oxide-based TBCs are known for their high melting point and excellent thermal stability. These coatings provide good insulation properties and are often used in high-temperature environments.
8. Aluminum Oxide (Al2O3)
Aluminum oxide-based TBCs, also known as alumina, offer good thermal stability and resistance to thermal cycling. These coatings are commonly used in a variety of applications, including aerospace, automotive, and power generation.
Types of Metallic-based TBCs
1. Platinum
Platinum-based thermal barrier coatings (TBCs) are known for their high-temperature stability and excellent thermal conductivity. These coatings are often used in gas turbine engines and other high-temperature applications where heat management is critical. Platinum-based TBCs provide superior protection against thermal stresses and oxidation, making them a popular choice in the aerospace and power generation industries.
2. Nickel
Nickel-based TBCs are widely used in various industrial applications due to their excellent thermal insulation properties and resistance to high temperatures. These coatings are commonly applied to turbine blades, combustion chambers, and other components in gas turbines. Nickel-based TBCs offer good thermal conductivity and low thermal expansion, making them ideal for protecting critical engine parts from heat damage.
3. Cobalt
Cobalt-based TBCs are known for their exceptional high-temperature performance and resistance to thermal cycling. These coatings are often used in applications that require superior thermal protection, such as in aircraft engines and industrial gas turbines. Cobalt-based TBCs provide excellent adhesion to the substrate and can withstand extreme temperature fluctuations, ensuring long-lasting protection for critical components.
4. MCrAlY-based TBCs
MCrAlY-based TBCs, where M represents a combination of metals like iron, cobalt, and nickel, are widely used in the aerospace industry. These coatings offer excellent resistance to high-temperature oxidation and corrosion, making them suitable for protecting turbine blades, combustors, and other components in aircraft engines. MCrAlY-based TBCs provide a strong bond with the substrate and help extend the lifespan of critical engine parts.
5. Aluminum-based TBCs
Aluminum-based TBCs are widely used in applications that require effective thermal insulation and protection against oxidation. These coatings are commonly used in gas turbines, industrial furnaces, and automotive engines. Aluminum-based TBCs provide excellent adhesion to the substrate and offer good thermal barrier properties, making them a cost-effective choice for heat management in various industries.
6. Iron-based TBCs
Iron-based TBCs are gaining popularity due to their high-temperature stability and resistance to thermal cycling. These coatings are often used in applications that require superior thermal protection, such as in gas turbines and power plants. Iron-based TBCs offer good thermal conductivity and low thermal expansion, ensuring reliable performance under extreme heat conditions.
Final Thoughts
Thermal barrier coatings (TBCs) are essential in various industries for their ability to protect materials from high temperatures and thermal stresses. There are different types of TBCs, including ceramic, metal, and polymer-based coatings, each with its own significance.
Ceramic-based TBCs, such as ThermaCote, offer excellent thermal insulation properties and can withstand extreme temperatures. Thermacote is the top choice for corrosion protection in commercial, residential, exterior, and interior applications. It is easy to apply and seals the envelope of any structure and protects from heat and corrosion. Looking for a TBC for your building? Contact us today to learn more.