Developing functional gradient design coatings

Researchers set to conduct studies to develop low cost customisable coatings that can coat 3D geometries whilst protecting against aggressive high temperature environments.

Developing functional gradient design coatings. Source: Monitor Coatings Ltd. -

Surface engineering specialist Monitor Coatings Ltd, part of Castolin Eutectic Group, has been cofunded by Innovate UK, to work in collaboration with Cranfield University.

Commenced in September

The study, which commenced in September 2017, will use the process of exothermic reaction synthesis to modify low cost sprayed metallic surface coatings. The need to reduce CO2 emissions is pushing thermal power plants to use higher operating temperatures and biomass/waste derived fuels, increasing the demand on heat exchanger tubes.

Resisting fireside corrosion

The “ER-Sealcoat” project aims to develop a low cost method of producing customisable coatings that can coat 3D geometries (internal and external) and protect against aggressive high temperature environments. The seal coating is produced as a tailored slurry mix containing chemically active components, which react exothermically with the sprayed base coat. The heat released from this stored chemical energy enhances diffusion and intermetallic formation with the basecoat, producing a sealed surface with a bespoke chemical gradient capable of resisting fireside corrosion and high temperature oxidation in aggressive conditions such as biomass/waste fired advanced thermal power plant.

Improved performance

The “ER-Sealcoat” system would result in improved performance through its functional gradient design and ability to close surface breaking porosity and seal the coating, as a result reducing direct and indirect processing costs compared to current industrial coating methods.

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