The Zircotec^® Coatings

Zircotec has developed a range of highly engineered plasma sprayed coatings that are able to protect components against the effects of heat, wear, abrasion and corrosion.

Our ThermoHold^® based ceramic coatings have been developed to significantly reduce heat transfer, providing lightweight and easily packaged coatings that can be used for various applications. Performance White^TM delivers the ultimate in thermal barrier performance for a range of applications. It has quickly become the mainstay of Zircotec's offering to motorsport, and is now used in a broad range of other automotive applications.

Zircotec has a number of other derivatives of its proprietary ThermoHold^® based ceramic technology. Our Performance Colours^TM Range offers some 13 different colour options; our Primary Range^TM offers a lower cost alternative to our high performance coatings, and our Diamond Black^TM Coating balances thermal efficiency with the provision of an extremely tough and durable finish. Click here for details of our full range of exhaust system coatings.

Composite Coatings

We have developed a range of coatings that are plasma sprayed onto carbon composite (and some plastics) to provide protection from heat, offer fire resistance, and protect against delamination and resin melt. Additionally, we can apply a heat-reflective coating for extra protection against radiant heat, or we can apply coatings that are resistant to wear, abrasion and stone chips. Adopted widely in F1, and with patents pending, our technology is attracting significant interest from other industries.

Ceramic Fabrications

Zircotec has the technology and know how to be able to manufacture some extremely complex ceramic structures. To do this we use an automated robotic plasma-spray facility, and, depending upon the component being fabricated, we use a combination of both sacrificial and permanent formers/dies on which the ceramic coating is deposited. An example of how we use this expertise is our manufacture of ultra high purity ceramic furnace linings (Susceptor Tubes) for the optical fibre industry.

Zircotec's areas of expertise include:

• Plasma-sprayed ceramic coatings for metals and composites, including carbon fibre composite
• Thermal management in motorsport, OEM, high performance cars and motorcycles, track day and classic cars.
• Thermal management in numerous other demanding applications.
• The application of surface coatings to protect against wear, abrasion and corrosion.

Our coatings are highly effective when used on engine exhaust system components including exhaust manifolds, exhaust headers, cat boxes, turbochargers and tail pipes, helping to protect heat sensitive components from the effects of heat. They reduce underbonnet temperatures, increase engine performance, help solve engine packaging issues and improve engine compartment safety. Based on Zircotec's proprietary ThermoHold^® formulation, these coatings can only be applied by Zircotec. Furthermore, patent applications have been filed to protect many of our coatings.

For any heat barrier and thermal management issues, Zircotec's technical specialists can provide advice no matter how demanding the requirements. Zircotec's specialists can also provide expert advice on a range of surface engineering issues.

Click here to go to our customer feedback page to see what our previous customers have said about Zircotec and its coatings.

Background

Formerly part of the UK Atomic Energy Authority, Zircotec's high temperature ceramic coatings, processes and technologies were originally developed for the UK nuclear industry. Most of our team of specialist scientists and engineers have followed Zircotec from its nuclear origins. They have continued to develop and refine Zircotec's high temperature coatings resulting in the high technology products that we supply today. Our technical development work is ongoing and continues to deliver new and improved products.

Zircotec's involvement in motorsport stretches back to 1994 when its proprietary ceramic coatings were first applied to rally cars. Our thermal coatings have been used across almost all forms of motorsport, they have been proven to be highly successful in the thermal management of high performance and classic car applications, increasing overall reliability and performance, and our coatings are now used on a broad range of vehicles from F1 cars to a number of production cars, trucks and buses. Additionally our coatings are now being applied to a range of performance parts for OEM's and also aftermarket suppliers. Zircotec's most common applications include automotive engine coatings, exhaust coatings, manifold coatings, turbo charger housing coatings, and carbon composite coatings. Applying high temperature thermal barrier coatings to these components can:

• Reduce underbonnet temperatures by up to 50^oC (122^oF), as independently measured & confirmed by DAMEX Race Engineering; click here for details.
  
• Increase engine performance, eg. just a 30^oC drop in intake air temperature can deliver a 6% increase in power, or can alternatively be used to deliver increased engine efficiency and hence less fuel usage.
• Enhance engine reliability - lower temperatures help to avoid the failure of critical engine components, eg. electronics.
• Extend the life of vulnerable components.

Zircotec operates to ISO 9001:2000 Quality Management Standards. Our quality systems are reviewed and approved by Lloyds Register.

We are proud to be active members of the Motorsport Industry Association.