Industrial Coatings in Automotive and Transportation Industries
- February 19, 2025
Introduction: The Role of Industrial Coatings in Automotive and Transportation
Industrial coatings are an essential element in the automotive and transportation sectors. These coatings aim to improve longevity, enhance performance and shielding against environmental harm. Different industry sectors utilise a variety of coating techniques, each offering unique benefits. However, thermal spray coatings stand out for their versatility in various applications, especially offering better protection against wear and corrosion. This article will explore key industrial coating methods, particularly thermal spray coatings, and their impact on advancements in the automotive and transportation sectors, including the involvement of the proposed CoBRAIN solutions [1].
Types of Coating Techniques in Automotive and Transportation
Different methods of coating are frequently used in the automotive and transportation industries, each serving various purposes. One example is electroplating [2], which uses electricity to cover surfaces with metal, providing improved resistance to corrosion, hardness of the surface, and a polished, appealing look, particularly beneficial for components such as bumpers and trim. Another common method is powder coating [3], where dry powder is applied to surfaces and then cured with heat, resulting in long-lasting finishes perfect for wheels and chassis parts that are resistant to chipping.
Electrophoretic Deposition (EPD) [4] is frequently used for intricate shapes and chassis, utilising an electric field to deposit particles from a solution onto surfaces in order to provide additional protection. Liquid coatings [5] are also widely used, especially for priming and painting outdoor surfaces, providing excellent UV protection and a lasting, high-quality appearance, however they need several coats for long-term effectiveness. Finally, thermal spray [6] coatings have gained recognition for their flexibility and excellent results, especially in demanding automotive uses, thanks to their capacity to improve resistance to wear and longevity.
Corrosion and Heat Resistance: Enhancing Durability and Efficiency
Thermal spray coatings offer two functions: corrosion resistance and thermal insulation, which are critical for automotive components operating in harsh environments. Exhaust systems and fuel tanks are especially susceptible to corrosion since they are constantly in contact with moisture, salt, and chemicals.
Ceramic and aluminum oxide coatings can help prevent rust formation and consequently increase the life of these crucial components. Thermal spray coatings do more than only protect against corrosion; they also operate as thermal barriers, insulating parts exposed to extreme temperatures. Heat from internal combustion engines and exhaust systems can have an impact on vehicle performance and structural integrity [7].
Applications in the Broader Transportation Industry
Thermal spray coatings play a vital role in multiple areas of the transportation sector including railway, aerospace, and marine fields. Train wheels and rail tracks endure significant stress that can be lessened by utilising wear-resistant thermal spray coatings. Thermal barrier coatings are used in the aerospace sector to allow turbine blades and exhaust systems to operate at higher temperatures, leading to improved fuel efficiency and reduced carbon emissions. Ships exposed to saltwater can use anti-corrosive thermal spray coatings to protect their hulls and metal parts, extending their lifespan and reducing maintenance costs [8,9].
CoBRAIN: Advancing Sustainable Coating Technologies for the Future
The CoBRAIN project is at the forefront of developing cutting-edge coating technologies that meet the evolving demands of sectors such as automotive and transportation. By focusing on high-quality coatings, sustainability, and resource efficiency, CoBRAIN plays a key role in advancing the future of industrial coatings. A central focus of the project is the development of high-entropy hardmetals (HEH), which exhibit exceptional hardness, wear resistance, and corrosion resistance properties that make them ideal for critical automotive and aerospace components like engine cylinders and turbine blades. In addition, CoBRAIN is pushing the boundaries of nanostructured coatings, enhancing their durability and mechanical properties to withstand the harsh conditions encountered in these industries.
Sustainability is another cornerstone of CoBRAIN’s mission. The project is dedicated to reducing reliance on scarce Critical Raw Materials (CRMs) like Tungsten and Cobalt by exploring alternative materials that maintain high-performance standards while reducing the environmental impact of manufacturing processes. With a focus on nanomechanics and microstructure analysis, CoBRAIN ensures that its innovative coatings not only perform exceptionally but also meet the strict sustainability and efficiency requirements of the automotive and transportation sectors.
Conclusion: The Future of Thermal Spray Coatings in Automotive and Transportation
With the ongoing evolution of the automotive and transportation sectors, the need for coatings that are efficient, sustainable, and high-performing will grow. Thermal spray coatings play a vital role in improving the performance of vehicles and extending the durability of parts through wear protection, corrosion resistance, and thermal control. These coatings are considered ground-breaking technologies because of their capacity to protect against wear, extreme temperatures, and environmental damage. The future of industrial coatings appears bright thanks to solutions like CoBRAIN brings on, which are driving innovation, especially in high-entropy alloys, nanostructured coatings, and sustainable materials. As thermal spray coatings continue to progress, they will stay at the forefront of innovation, driving the automotive and transportation industries toward increased efficiency and environmental sustainability [10].
References
- Oerlikon Metco. (n.d.). Thermal spray coating services: Coatings, Oerlikon Metco, Accessed October 14, 2024, https://www.oerlikon.com/metco/en/products-services/thermal-spray-coating-services/coatings/
- Schlesinger, M., et. al., Modern electroplating, John Wiley & Sons, 2011
- Conesa, C., et. al., Characterization of flow properties of powder coatings used in the automotive industry. Kona powder and particle journal, 2004
- Verma, K., et. al., Parallel simulation of electrophoretic deposition for industrial automotive applications, 2018 International Conference on High Performance Computing & Simulation (HPCS), 2018
- Bhuiyan, M, et. al., Automotive coating industry: Sustainability challenges and smart innovations. In Challenges for Technology Innovation: An Agenda for the Future, CRC Press, 2017
- Thakur, L., et. al., Thermal Spray Coatings, CRC Press, 2021
- Bogdan M, et. al., A Comprehensive Understanding of Thermal Barrier Coatings (TBCs): Applications, Materials, Coating Design and Failure Mechanisms. Metals, 2024
- Mehta A, et. al., Processing and Advancements in the Development of Thermal Barrier Coatings: A Review, Coatings, 2022
- Allied Power Group. Types of coatings for gas turbine blades, Allied Power Group website, Accessed October 14, 2024
- Bhaskaran N. R., et. al., High-Entropy Alloy Coatings Deposited by Thermal Spraying: A Review of Strengthening Mechanisms, Performance Assessments and Perspectives on Future Applications. Metals, 2023
