New low cost thermal barrier coating developed for diesel engine applications to solve heat issues associated with 2013 Euro VI emissions introduction

Fifty percent lower cost thermal barrier coating provides long lasting thermal barrier solution to solve heat issues created by changes to emissions standards of diesel engines.

OXFORD – A new low cost, fit and forget ceramic coating offering surface temperature reductions of 125°C has been developed for diesel engine applications. Developed by coatings specialist Zircotec, its new ceramic formulation, together with changes to the manufacturing process have enabled the firm to reduce the costs by fifty percent for its new Performance Diesel™ product. The coating provides an attractive option for truck and bus manufacturers challenged by the higher temperatures experienced with new Euro VI emissions regulations and testing methods set to be introduced in late 2013. “Euro VI will require manufacturers to further reduce NOx and particulate matter,” says Zircotec’s sales director Peter Whyman. “There are also changes to the test cycle including cold start and soak test. During running, engines are running hotter and in these conditions, improved thermal management is likely to help the manufacturers improve performance and overall engine reliability. This is particularly relevant for some after treatment systems,” Zircotec’s new Performance Diesel coating can be applied to exhausts, turbochargers as well as on plastic heatshields to effectively manage heat, protect other components and help emissions controls systems work at their optimum. “From our discussions with engine manufacturers and OEMs, heat management is more crucial with Euro VI,” adds Whyman. “Whether this is for SCR engines where getting the catalyst warm is key, or in general terms, the engines are running hotter with heat soak to other components under the engine bay risking poor reliability. We now have a durable, yet cost effective solution and unlike some lagging products that require reapplication, we can offer reliability throughout the vehicle’s life.” With engine costs rising significantly due to the addition of emissions equipment to meet the regulations, Zircotec believes its Performance Diesel coating offers OEMs a method to save costs on the whole life of the vehicle. “Use of our Performance Diesel coating can enable engineers to solve existing heat issues without a major redesign of the engine bay as well as offering the opportunity to delete heatshields, claims Whyman. “As a fit and forget solution, whole life costs are lower too.” The coating is applied using plasma spraying, in effect welding the coating to the substrate. It can be applied to most metals as well as many plastics and composites, in the latter preventing delamination. A bespoke patent pending process, created by Zircotec ensures that even plastics are unaffected by the plasma spray process. Zircotec is already trialling the coating with OEMs and expects results of the testing to be available later this year. About Zircotec Zircotec offers a wide range of plasma sprayed ceramic and metallic coatings that protect components against the effects of heat, wear, abrasion and corrosion. Lightweight and easily packaged, Zircotec’s technologies can be applied to a broad range of different materials including metals and composites. Proven in F1 and the nuclear industry, the technology is now trusted by car manufacturers, industrial users, car enthusiasts and an increasing range of other applications to effectively manage heat and wear, enhancing performance and reliability. ZircoFlex™, the latest development from Zircotec, offers for the first time, a truly flexible ceramic coating.