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Ceramic/Aluminium Coating

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When performance really counts

Power is created by combining fuel and oxygen, then igniting this mixture. This ignition leads to a rapid rise in temperature as the mixture burns, pressure increases rapidly and forces the piston down the bore. Hence power is produced.

However, much of the heat generated ends up in areas which don’t contribute to power output.
In fact it has been estimated that 70% of the potential energy in the fuel ends up wasted out of the exhaust pipe or fed into the cooling system.

Anything that can reduce this heat loss will result in an increase in power output.
This is where a thermal barrier coating, relatively new to the automotive industry, is beginning to make it’s mark.

Thermal Barrier Coating
A thermal barrier coating applied to the piston crown, valves and combustion chamber will increase combustion temperature whilst reducing heat loss into the piston (therefore into the engine oil), cylinder head water jackets and incoming charge.

Boyles law tells us that the volume or pressure of the gas must increase if the temperature goes up.

By keeping a larger portion of the heat within the combustion space pressure on the piston is increased, flame propagation and travel is enhanced.
Test engines have recorded up to eight percent increases in horsepower from this treatment alone.
Less heat into the piston rings also means that radial ring tension has an increased life expectancy.

Piston designers and engine builders will also be pleased with the opportunities presented to improve the basic design of the piston by virtue of the thermal barrier.
The reduced heating effect on the piston can also allow piston-to-bore clearances to be reduced in some instances.
This can lead to more effective compression rings and more effective oil control rings, simply because the rings are more accurately located in relation to the bore.

Thermal Barrier Coating
Aluminium loses its strength very rapidly as temperature rises.
Pistons are made thick in certain areas to give sufficient strength at the elevated temperatures normally encountered.
It may now be possible to run lighter pistons due to the thermal barrier.70% .....ends up wasted out of the exhaust pipe or fed into the cooling system.
The closer the top ring land is to the piston crown , the better the combustion process is. In the past the major restriction has been that placing the top ring too close to the top of the piston causes the ring land to collapse because the intense heat cannot be dissipated. Coating the piston crown means the top ring land will operate at a far cooler temperature.

Thermal Barrier Coating has the same coefficient of expansion as aluminium. Particles are bonded with an inorganic binder which is unaffected by petroleum products.
With a bond strength of 10,000 psi., this coating’s non-porous ceramic matrix improves flame travel, reduces oil temperature, increases radial tension life of rings and prevents carbon build-up.
Arguably no part of an engine undergoes greater thermal shock than pistons and valves.
Yet this has no effect on the bonding properties of the Thermal Barrier Coating.

Piston damage - detonation
One of the major causes of piston failure is detonation.
When a ceramic coating is applied to a piston top and a combustion chamber, it will increase the heat retained by combustion and this in turn may cause bad detonation.
There should be an adjustment made to engine tune to compensate.**

What makes Ceramic/Aluminium coating so superior to traditional high temperature coatings is its metallic-ceramic structure.

Combining the benefits of aluminium and ceramics in a single coating. (more).....