To extend the service life of high-temperature resistant coatings, the following key aspects can be addressed:
Optimize the usage environment
Temperature control:
Strictly control the working temperature: try to ensure that the coating works within its specified temperature range, and avoid prolonged exposure to high temperature environments close to or exceeding the temperature limit. For example, for coatings with a temperature resistance of 800 ℃, if the operating temperature of the equipment can be frequently controlled below 700 ℃, the performance of the coating can be more stably maintained, delaying the occurrence of problems such as aging and cracking.
Reduce temperature fluctuations: For equipment that operates intermittently or experiences frequent temperature changes, appropriate insulation and heat preservation measures can be taken, such as adding insulation layers to slow down the rate of temperature change during startup and shutdown, reduce the thermal stress caused by coating expansion and contraction, and minimize coating peeling, cracking, and other issues caused by accumulated thermal stress.
Environmental media management:
Isolate corrosive substances: Whenever possible, minimize contact between the coating and corrosive gases (such as sulfur dioxide, hydrogen sulfide, etc.), liquids (such as acid-base solutions) by setting up protective barriers, sealing devices, and other means. For example, in chemical reaction vessels, corrosion-resistant lining materials are used to separate the reactants from the vessel wall coating, avoiding direct corrosion of the coating by corrosive media.
Purifying the air environment: For equipment in high-temperature environments with high levels of dust particles and impurities, such as cement plants, thermal power plants, etc., air filtration systems can be installed to reduce the content of dust particles in the air, reduce their impact on the surface of coatings, and extend the protection period of coatings.
Improve the quality and adaptability of the matrix material
Surface treatment of substrate:
Do a good job in pre-treatment: strictly follow the process requirements to remove oil, rust, and polish the surface of the substrate, so that the surface is clean, dry, and the roughness reaches the appropriate range (generally 30-50 μ m is suitable), enhancing the adhesion between the coating and the substrate. For example, using sandblasting to treat steel substrates can effectively remove rust and impurities, while also forming appropriate roughness, providing a good adhesion foundation for coatings and making them less prone to detachment during use.
Ensure substrate quality: Select high-quality and stable substrate materials to avoid defects in the substrate itself (such as internal pores, inclusions, etc.) affecting the adhesion and service life of the coating. At the same time, it is important to pay attention to key performance parameters such as the thermal expansion coefficient of the substrate material, and try to choose a substrate material with a thermal expansion coefficient similar to that of the coating, in order to reduce the thermal stress caused by temperature changes and prevent the coating from peeling or cracking due to excessive thermal stress.
Improve the performance of the coating itself
Select high-quality coating materials:
High temperature resistant materials: Based on the actual working temperature requirements, priority should be given to selecting coating materials with higher temperature resistance and more stable performance. For example, in high-temperature extreme environments such as aerospace engine thermal components, ceramic based high-temperature resistant coatings (capable of withstanding temperatures above 1000 ℃) are selected. Compared to organic silicon coatings, they can better resist high temperatures and maintain effective protection for a longer period of time.
High performance functional coatings: Based on specific application scenarios, select coatings with multiple excellent properties, such as coatings that are both heat-resistant, corrosion-resistant, and wear-resistant. For example, in the metallurgical industry, high-temperature resistant and wear-resistant metal ceramic composite coatings are used on high-temperature rolling rolls, which can not only cope with high temperature environments but also resist wear caused by rolling material friction, extending the service life of the coating.
Optimize coating structure:
Multi layer composite coating: Design and adopt a coating system with a multi-layer composite structure, such as using a strong adhesion primer for the bottom layer, a functional layer in the middle layer that provides the main performance (such as high temperature resistance, insulation, etc.), and an outer layer coated with a topcoat that has weather resistance, corrosion resistance, and other protective functions. Each layer cooperates with each other to play a synergistic role, ensuring the protective effect of the substrate from multiple aspects and extending the overall service life of the coating.
Gradient coating: constructing coatings with gradient changes in composition or performance, making the bonding between the coating and the substrate as well as between the layers of the coating more natural, with more uniform stress distribution, reducing stress concentration problems caused by interface differences, and improving the stability and service life of the coating. For example, the application of gradient ceramic coatings on some high-temperature metal components gradually changes the ceramic composition from the substrate to the coating surface, effectively improving the adhesion between the coating and the substrate as well as the overall thermal shock resistance.
Strictly control the construction process
Standardize the construction process:
Strictly follow the steps for construction: Operate according to the construction sequence and requirements specified in the coating product manual, including the mixing, blending, coating methods (such as spraying, brushing, rolling, etc.), coating layers, and drying time of each layer, all of which must be strictly controlled. For example, when mixing two-component coatings, accurately mix them according to the specified ratio to ensure stable coating performance; During the coating process, ensure that each layer of the coating is uniform, free of omissions, sagging, and other phenomena, so as to achieve the best overall quality of the coating.
Control the construction environment: Pay attention to the environmental conditions during construction, such as temperature, humidity, ventilation, etc., to meet the requirements. Generally speaking, the construction temperature should be controlled between 5-40 ℃, and the air humidity should be less than 80%. Construction in a suitable environment helps the coating to cure better, form a good structure, improve coating quality, and thus extend its service life.
Conduct quality inspection and maintenance:
Post construction inspection: After the coating construction is completed, quality inspection should be carried out in a timely manner. A coating thickness gauge should be used to check whether the coating thickness meets the standard. The adhesion between the coating and the substrate should be checked through testing methods such as grid cutting. Any parts that do not meet the requirements should be repaired and rectified in a timely manner to ensure that the coating quality is qualified before being put into use.
Regular maintenance and inspection: During the use of the equipment, the coating should be regularly inspected to observe whether there are any signs of discoloration, cracking, peeling, wear, etc. on the surface of the coating. Once problems are found, timely repair measures should be taken, such as local re coating, to prevent the problem from further expanding, maintain the protective function of the coating, and extend its service life.

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High termperature curing polysilazane, pls check IOTA 9108, IOTA 9118.