Thermal Barrier Coating -
Where Heat Stops and Reliability Begins
Efficient Insulation. Engineered Peace of Mind.
Plasma Spray Processors provides Thermal Barrier Coating (TBC) services in India using Yttria-Stabilised Zirconia (YSZ) applied via atmospheric Plasma Spray. TBC systems insulate metallic substrates from temperatures exceeding 1,000°C, significantly extending the service life of gas turbine blades, combustion liners, boiler tubes, and piston crowns. With ISO-certified application processes and 40 years of thermal spray expertise, we serve aerospace OEMs, power utilities, and industrial clients across India.
Request a CallbackWhat is a Thermal Barrier Coating?
Think of TBC as your part’s very own “thermal armour” - a multilayered ceramic shield that keeps critical engine, turbine, or industrial surfaces running cool, even when things outside are seriously hot.
- Bond coat bonds it all together.
- Ceramic topcoat keeps the heat at bay, usually Yttria-stabilised Zirconia.
- Thermally grown oxide (TGO) layer for durability in harsh environments.
End result? Less heat where it does not belong, more life from every component.
Why Choose TBC from Plasma Spray Processors?
Up to 250°C lower metal temperatures, fewer surprises from sudden heat spikes.
Exceptional Thermal Insulation
Up to 250°C lower metal temperatures, fewer surprises from sudden heat spikes.
Handles the Heat
Ceramics tested for life at up to 1200°C, well above what most equipment ever sees.
Defends Against Oxidation & Corrosion
Specialized bond coats for long-term chemical and atmospheric resistance.
Lasts Longer (So You Can, Too)
Resists spalling, shock, and cycling, keeps your workflow uninterrupted.
Thermal Barrier Coating Materials:
| Sr No. | Material | What It Offers | Ideal Applications |
|---|---|---|---|
| 1 | Yttria-Stabilized Zirconia (YSZ) | Low thermal conductivity, high thermal shock resistance, stable up to ~1200°C | Gas turbines, diesel engines, aerospace components |
| 2 | Mullite | Low density, good mechanical strength, corrosion resistant, stable below 800°C | Diesel engines, lower temperature thermal barriers |
| 3 | Alumina (α-Al2O3) | High hardness, chemical inertness, high thermal conductivity | Added to YSZ coatings for improved oxidation resistance |
| 4 | Ceria (CeO2) + YSZ Blend | Improved thermal shock resistance and insulation | Enhanced YSZ coatings for thermal cycling |
Where Do TBCs Shine?
-
Turbine blades, vanes, combustors (Aerospace and Power)
-
Hot gas path and flame tubes
-
Exhausts, turbochargers (Automotive)
-
Reactors, high-enthalpy equipment (Process Industries)
If heat is the enemy, TBC is your easy win.
How It Works (No Surprises, Just Results)
Blast & Prep
Clean, grit-blasted surfaces for the best bond.
Bond Coat
NiCrAlY - classic, proven, and ready for duty.
Plasma Spray Ceramic Layer
YSZ topcoat, custom thickness, low porosity, applied with precision.
We Test. You Relax.
Every coating is measured, checked, and qualified to ISO/ASTM standards.
Technical Snapshot
-
Thickness: 100–300 µm (topcoat)
-
Hardness: 900–1200 HV0.3
-
Thermal Conductivity: ≤1.5 W/m·K
-
Operating Range: up to 1200°C
-
Bond Coat: NiCrAlY/MCrAlY, 75–150 µm
Why Work With Us?
Decades Doing This
40+ years of “seen it, solved it, coated it.”
ISO Process
Materials and controls that set the standard (and keep audits stress-free).
Proven Results
Reference case studies and technical data available for review.
It's Literally Custom
Every job is tuned for your environment and expected service life.
Frequently Asked Questions
Ready to Turn Down the Heat?
Let’s talk about a TBC solution that keeps your next project moving forward, with none of the guesswork.
Plasma Spray Processors - Thermal Barrier Coatings. More uptime, less worry.
Areas We Serve
Maharashtra | Gujarat | Tamil Nadu | Telangana | Andhra Pradesh | Karnataka
Mumbai | Navi Mumbai | Pune | Sangli | Rajkot | Baroda | Chennai | Coimbatore | Hyderabad | Bangalore
Get in touch with our experts today for a customized quote and consultation.
Get a Quote
+91 9820718722 
