The Zircotec Ceramic Coating Process showing how our ceramic exhaust coating is applied

Behind the scenes at Zircotec showing how its ceramic coating is applied as an exhaust coating, manifold coating and turbocharger coating to deliver Zircotec's high thermal barrier performance, high quality and attractive finish.

[@rhinoshieldjacksonville4969]

Ceramic coatings are used for everything now it is such wonderful technology!

[@Zircotec]

Hi netmatrix75. All of our ceramic coatings are applied using plasma spraying. This process allows us to spray our ceramic formula onto the substrate material at extremely high temperatures (~10,000degC) to ensure strong adhesion. It also gives us a large number of parameters to control which we can use to adjust the coating to meet specific needs. You can read in greater detail on our plasma-spray processing technical page on our website.

[@Zircotec]

Hi lillskiten1337. Although increasing the coating thickness would increase the overall temperature drop, these gains diminish (as you rightly suggested). The downside of increasing the coating thickness is increased cost and processing time, and also an increased risk of coating failure. Zircotec coatings are therefore specified to balance the coating thickness with overall coating performance and cost. As such, increased thicknesses are suitable only for some very special applications.

[@Zircotec]

Hello Guds777. Our coatings are primarily used to reduce heat transfer from exhaust pipes. This effect gives some secondary effects which increase engine performance: - Lower underbonnet temperatures give lower air intake temperatures which leads to increased engine power. - Keeping more heat inside the exhaust gas gives a higher exhaust gas velocity, increasing cylinder scavenging, and allowing turbochargers to spool up more quickly.

[@expertwebworld6189]

ceramic coating in modern technology & its wonderful

[@specialized29er86]

I'm wondering if the application process has been updated in the last 5 years? or is it the same as 2012.

[@Zircotec]

Thanks rabgallacher! We only apply our ceramic coating to the external surfaces. We understand some companies offer internal paint coatings, however surface preparation of internal surfaces is near impossible and this combined with the extreme conditions inside an exhaust manifold make paint detachment likely. For more information please visit our FAQ's page on our website, or just give us a call.

[@beachboardfan9544]

Do I need to do any prep to my header before sending it to be coated? Like blasting it clean or stripping paint...

[@RocketRaven]

I wonder if you doubled the thickness of the layer, how much in a drop of temperature would that mean? If with that coating thickness meant 300 degrees drop could we maybe see another 50 degree drop. If the coating were to be double the thickness? So that we get a surface temperature of 250 instead.

[@blubunn]

At 3:06 it shows a dyno readout with exhaust gas temps at 560 degrees. It then states the exhaust temperature is 700 degrees. How does that happen?! Where does the extra 140 degrees come from? Then they show another dyno readout(after coating) at 3:36 where the exhaust temps are only 460 degrees... and tell us the exhaust temps are 400 degrees. Yeah... so? The exhaust temps were 100 degrees cooler in the second test to start with. Small wonder the surface temp went down 100 degrees. Notice we don't see the thermocouple or laser thermometer ourselves. Why not "paint" half a header with the stuff and show us a laser thermometer reading the surface temperatures of each side in real time. That would be a real test.

[@wantboost]

blubunn Exhaust temperature is referring to the physical temperature of the exhaust pipe. Exhaust gas temperatures will almost always be higher than the temperature of the physical piping due to the speed at which the gasses move through the piping, the ability of the piping material to transfer heat to the surrounding ambient air, thickness of the piping, piping material, and so forth.

[@TheAmericanUhate]

Heat builds on surfaces. Same reason your car can reach 140 degrees inside on a 100 degree day. Lol all that typing instead of just using your head.

[@gullenberg]

When for example header is coated with zircotec,can it be inside coated with ceramic coating?

[@defifthelement]

can it be used on typical cast manifold? Can it be used on interior of manifold or only exterior? Many thanks for info

[@georgewhite6493]

Is there a specific reason that the coating wasn't applied inside the ports of the exhaust? Is it too tricky to do with the gasket surface there? I noticed you used a tape to cover the entire gasket end. I'm wondering if getting about 1 to 2 inches in the actual port lip would be useful in reducing the temperature or not?

[@Zircotec]

Hello George. Our ceramic coating has a thickness of 300 microns, which means we have to mask off the gasket.

[@nb02210]

Looking to coat exhaust headers and would like them black. Is that possible?

[@goutvols103]

Are you able to coat the inside of the headers as well?

[@L88v]

where can i get this done in Canada?

[@netmatrix75]

If the application method also the same like Plasma Spraying?

[@raduurdea6193]

What is the material/layer/tape that you apply for masking the component from being sprayed?

[@Zircotec]

Hello Radu. We use a special tape that can support high temperatures while we ceramic coat the parts.

[@raduurdea6193]

yes, thanks for that I kind of figured it myself :).....that's why I'm asking. Which material is it? How is it called? where can I find it? Is it custom made just for ceramic spray aplication? Link or something? Thanks in advance

[@maljsmi]

Zircotec hi can i send my exhaust from UAE for coating

[@Zircotec]

Hello Mohammed. Yes, you can. Just send us an e-mail to [e-mail] so we can give you a quote for your exhaust. Regards, Ricardo

[@dimmacommunication]

Can you threat titanium?

[@farhanwartiansyah6258]

What the powder material ?

[@elromed]

Price?

[@idjr2654]

Do you guys have a place of business in the USA?

[@Zircotec]

+idjr Yes and No. Yes for our ZircoFlex heatshield products. You can contact Thermal Control Products (www.thermalcontrolproducts.com). No for our coatings because they have to be applied at our facilities. Zircotec's plasma-spray processing is a specialised high temperature industrial process that we developed and first used within the UK nuclear industry. We use an electric arc to produce high temperatures ~10,000°C (18,000°F) in a control gas. We use this heat to melt the coating material (even Zircotec's ceramic melts at these temperatures) and immediately spray this melt onto the component that is to be coated. We control the overall system so that when the spray hits the surface it solidifies and in effect "welds" itself to the surface. Our ceramic coating is a near pure solid ceramic material that is melted within our process and directly hot sprayed onto the surface to be coated. When this molten ceramic hits the cold component surface it immediately solidifies and "welds" itself in place, producing a very firmly attached ceramic coating. Our ceramic coating must be applied by Zircotec. It is simply not a paint! Our coatings can only be applied using Zircotec highly specialist plant and equipment, and involve our own proprietary processes and materials.

[@oscarianxi478]

It would be more efficient to coat the inside of the exhaust tubing, and oh turbo blades as well, so you can utilise the heat-release of the exhaust tubing still, while reducing all that heat, before it even enters the tubing's metal itself. *(Do you understand what I mean? :/ **skrunches chin**)

[@hellcatdave1]

Lol coating the inside of the turbo. Funny.

[@16vastraturbo]

+DavidMN whats funny about that???

[@hellcatdave1]

16vastraturbo No real purpose. Not to mention turbos have pretty tight tolerances. Coating the turbo blades would be a horrible idea.

[@16vastraturbo]

+DavidMN well that would be taken into consideration when making the blades or turbine most coatings are in the microns anyway so you wouldnt even notice a coating was on.

[@DoriFord]

Actually, Porsche had ceramic inserts inside exhaust ports in their turbocharged aircooled engines, so it works. Just to let you know.

[@barbarabrewer9623]

9mb woot woot

[@TheShangralaaaa17]

all this rusts and looks like ass after the first heat cycle

[@Zircotec]

+TheShangralaaaa17 Hello. We apologise if you have a product that you're not happy with. We pride ourselves in our solutions and we have many customers within the Motorsports industry (including F1) and a wide range of retail customers that have been using our ceramic coatings and are very happy with benefits and heat management solutions. Lots of our customers use and re-use their cars on extreme environments and the coatings still doi their job as a thermal barrier - as they always should do. If you have a ceramic coating that, by any chance is rusting, please contact us via our mail ([e-mail]).

[@THEpowerBYyo]

Zircotec