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Introduction To Coatings
Coatings fall into four main categories. Some coatings may fall into more than one category.
Dry film lubricants, also known as solid film lubricants, provide a lubricating film that reduces friction, inhibits galling and seizing and in some instances can aid in dispersing heat. They are slippery and provide an extremely low coefficient of friction.
The two most important components are binders and lubricating ingredients. Without a good binder the coating will not stay in place and will simply clod flow or buff off in operation. Similar coatings using the same pigments but different binding systems can show a wide a wide variation in load carrying abilities, ranging from 100,000 psi to over 350,000 psi. The pigments determine the actual lubricating potential. PTEF, as an example, is listed as having the lowest coefficient of friction (COE). However, under high speed and load, the COE of PTFE degrades while that of MOS2 (Moly) improves, until it is significantly better than PTFE.
One of the obvious reasons for using a lubricating coating is to reduce friction, which improves wear, extends part life and frees up H.P. normally lost to friction. A second major benefit is a reduction in part temperature. This is especially important to such parts as valve springs. Here the pigment choice is critical as certain ingredients can trap heat in a part. It is recommended that coatings using PTFE be avoided in these cases.
Thermal barrier coatings are designed to reduce the heat movement of heat. In some instances, such as exhaust systems, you want to keep the heat within the part. In combustion chambers you want to use the heat generated by combustion to push down on the piston rather than bleed off into surrounding surfaces. Continued testing has shown that simple thermal barrier action is not the only characteristic that is important. In fact certain TBC’s will move an engine into detonation. TBC coatings can be made from a variety of materials. Ceramics get the most attention, though there are other materials that are superior in specific applications.
Being able to move and control heat is of tremendous importance. Excessive temperature can lead to metal fatigue, boiling fluids, damaging metal expansion, reduced electrical efficiency and a host of other problems. Traditionally dealing with heat has been handled either by expanding the radiating surface, constructing parts from materials that are more heat conductive and using the color black. With advances in thermal management methods additional ways of enhance heat transfer now exist. Our coating is capable transferring heat faster than a bare metal surface. The coating does use the color black, but it is more than a simple “black body” heat emitting coating. It includes ingredients that also contribute to increase heat flow. Combining these properties with increased corrosion protection and thin film application technique maximizes thermal transfer capabilities. Effective on brakes, intake manifolds, cylinder heads, oil pans, radiators, intercoolers, and many more parts. Certain dry film lubricants are capable of reducing part temperature not only through the reduction of friction, but also through increased thermal flow. The active ingredients accelerated the movement of heat. This is especially beneficial on valve springs where excessive heat can lead to accelerated fatigue and in some instances breakage.
The loss of effectiveness, reduction in part life and deteriorating appearance due to corrosion/chemical damage is of real importance. Loosing a well matched/tuned header to rust is not only expensive, but also frustrating. A good aluminum manifold can become junk if the water inlet area corrodes excessively. Keeping components clean and attractive is of concern when promoting your vehicle or the parts you manufacture. We offer a variety of protective coatings that also enhance the appearance of a part. Many of these coatings will have additional benefits such as thermal barrier or thermal dispersants capabilities.
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