Ceramic-based thermal coatings have evolved to encompass a new, flexible coating developed by Zircotec, offering easy-to-apply, lightweight protection for heat sensitive surfaces

As the management of heat becomes increasingly important for manufacturers striving to increase production efficiency while reducing carbon emissions, the use of thermal barriers can play a vital role in reducing heat transfer and protecting heat sensitive surfaces.  Thermal management specialist Zircotec, traditionally known for its plasma-sprayed ceramic coatings, has developed what is believed to be the first ever flexible ceramic heat shield material: ZircoFlex. The new, lightweight coating offers a robust and durable solution for the thermal protection of heat sensitive components and is easily applied to the material surface using either clips or double-sided adhesive tape. The product can be used in a host of applications and can be easily applied to a wide range of materials.

Easily applied
Zircotec’s plasma-sprayed ThermoHold based coatings are already used for the protection of metallic and composite components in an increasing number of applications, including automotive, marine and aerospace. Prior to the development of ZircoFlex, the company had treated components directly using 14,000ºK plasma sprays at its factory in Oxfordshire. However, the new coating is supplied as a roll of thin, aluminium backed foil and can be applied directly by the end user.

Safer for employees
“ZircoFlex manages heat efficiency, reducing heat loss and helping to make industrial processes more energy efficient and economical to manage,” explains Zircotec sales director Peter Whyman. “It is applied to the material surface as a lightweight layer, and can reduce surface temperatures by up to 64 percent. Applying ZircoFlex to heat sensitive materials also offers distinct safety advantages, as it lowers the risk of staff sustaining serious burns injuries if they come into contact with high temperature surfaces.”

Lightweight at only 460g/m2 and only 0.25mm thick, ZircoFlex can be easily cut and installed by hand or machine, and fixed in place using mechanical fasteners or high temperature adhesives, allowing it to be integrated directly into existing equipment.

Flexible
Ceramic coatings are naturally brittle, which has previously limited their use to rigid substrates. The new, flexible ZircoFlex coating, which is the culmination of more than five years’ intensive research and materials science, uses an innovative technology whereby the ceramic coating is sprayed in the form of thousands of individual ‘platelets’ onto the surface of an aluminium foil. While they are close-packed to provide robust heat protection, this structure allows the foil to be bent and manipulated to suit different geometries. The coating can even be folded tightly through 180° without damaging the thermal barrier.

Long lasting
ZircoFlex is highly durable and does not require regular maintenance or replacement, providing a cost effective and easy to maintain solution. Zircotec’s plasma-sprayed ceramic coatings are already in use in coal-fired power stations for the thermal protection of oil wiper blades, where the coating will typically not need to be inspected for four years.
For further information or to make an enquiry about ZircoFlex, please visit www.zircotec.com.