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The principle and mechanism of why high-temperature resistant coatings can withstand high temperatures

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The characteristics of the material itself
Choosing high melting point materials: Ceramic materials such as alumina and zirconia are often used for high-temperature resistant coatings. They have extremely high melting points, with alumina reaching a melting point of 2072 ℃ and zirconia reaching a melting point of around 2715 ℃. Based on them, they can remain solid in high-temperature environments and are not easily melted, thus withstanding high temperatures. There are also some intermetallic compounds (such as nickel aluminum, titanium aluminum, etc.) whose special lattice structure forms strong interatomic bonding forces, can withstand high temperatures, and have good structural stability at high temperatures.
Having a low coefficient of thermal expansion: A material with a low coefficient of thermal expansion means that its volume change is relatively small when the temperature increases. For example, some silicon carbide based coating materials have a small coefficient of thermal expansion. When subjected to rapid heating in a high-temperature environment, they will not generate excessive internal stress due to thermal expansion and contraction, which will cause the coating to crack or peel off. They can maintain structural integrity and thus maintain high temperature resistance.
Structural design of coatings
Multi layer structure: Adopting a multi-layer coating system, for example, the bottom layer can choose a material with strong adhesion to the substrate material and the ability to buffer thermal stress, which can enhance adhesion and alleviate stress; The outer layer is made of materials with excellent properties such as high temperature resistance and oxidation resistance, which directly face the high temperature environment. The layers work together to enhance the overall high temperature resistance.
Gradient structure: Construct a coating structure with a gradient change in composition, where the composition of the material gradually transitions from the side connected to the substrate to the coating surface, allowing for more uniform dispersion of thermal stress and avoiding stress concentration at the interface due to sudden changes in material properties, effectively improving the stability and resistance of the coating at high temperatures.
Antioxidant and anti-corrosion resistance
Oxidation resistance: Many high-temperature resistant coatings add elements or compounds that can form a dense oxide film. For example, in chromium containing coating materials, in high-temperature aerobic environments, chromium will preferentially react with oxygen to form a continuous and dense chromium oxide film. This film can prevent oxygen from further diffusing into the interior of the coating, avoiding further oxidation of the coating substrate and maintaining good performance in high-temperature oxidation atmospheres.
Corrosion resistance: In environments with high temperatures and corrosive media (such as sulfur, alkali metals, etc.), coatings resist corrosion through their own chemical stability and the formation of protective corrosion product layers. For example, some high-temperature resistant coatings doped with rare earth elements can improve the microstructure of the coating, enhance its ability to resist thermal corrosion, and enable the coating to function normally in harsh high-temperature corrosion environments.
Good adhesion with the substrate
Appropriate bonding process: Advanced processes such as thermal spraying, chemical vapor deposition, and physical vapor deposition are used to prepare coatings, which can form strong chemical bonds, mechanical interlocking, and other bonding methods between the coating and the substrate, ensuring that the coating will not easily detach from the substrate at high temperatures. As long as the coating is tightly bonded to the substrate, it can better exert its high temperature resistance characteristics and continue to protect the substrate.

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