Plasma-Sprayed Ceramic Coatings for Aerospace

Ceramic coatings have become a critical technology in the aerospace sector, driven by advancements in materials and processing capabilities. Technical ceramics can now be applied as uniform coatings that enhance the performance of underlying substrates. These plasma-sprayed ceramic coatings offer significant improvements in component durability and operational efficiency.

**Why Use Ceramic Coatings in Aviation?**

Engineers choose specific ceramic coatings to enhance the thermodynamic and chemical properties of base metals used in challenging aerospace environments. These coatings are selected to improve resistance to corrosion, high temperatures, and wear in critical components such as afterburners, turbine blades, combustors, nozzle guides, and transition ducts. The challenge lies in uniformly coating base parts with ceramics that have high melting points, and plasma spraying provides an effective solution to this issue.

**The Basics of Plasma Spraying**

Plasma spray coating is a precise method for applying a wide range of materials onto suitable workpieces. It involves using sophisticated equipment including a plasma torch and powder injector to heat feedstock particles. These particles are then directed at high velocity onto a relatively cool substrate, where they rapidly cool and adhere to form a durable coating.

The primary advantage of plasma spraying is its ability to deposit materials with extremely high melting points, such as zirconia (2715°C).

**Case Study: Plasma Sprayed Zirconia**

Yttria-stabilized zirconia (YSZ) is an excellent material for thermal barrier coatings due to its low thermal conductivity. However, its high melting point makes it challenging to deposit using most thermal spray processes. Plasma spraying overcomes this challenge by providing sufficient thermal energy to melt these materials and deposit them effectively on the workpiece.

In a typical plasma spraying setup, a single electrode pair initiates ionization of inert gas (argon, nitrogen) flowing through a constricted nozzle. Zirconia powder is then fed into the extended plasma plume, where it is heated to melting point and propelled onto the workpiece. This process results in a high-performance thermal barrier coating that effectively insulates base metals from extreme heat in demanding operational environments.

**Plasma Sprayed Aerospace Components**

CrownRe Coating Solutions specializes in providing plasma spraying equipment and thermal spray powders for aerospace applications. Whether you are interested in our feedstock powders or acquiring high-power plasma systems for efficient thermal spray processes, our team is ready to assist you. Contact us today to learn more about optimizing your aerospace coatings with advanced ceramic solutions.