This is an application of Ceramic Coating in the field of Automotive , Especially in Formula One . The exhaust system to be shielded to protect the heat damage to the nearby carbon fiber parts. for this reason Ceramic Coating is done. Special thanks to company Zircotech for this technology.

1. Exhaust Heat Management By
Ceramic Coatings in Formula one
By,
Akheel Ahamed
MSc in Mechanical Engineering
Hochschule Rheinwaal 1

2. Design Problem
• Application: Formula 1 Car Engine Exhaust
• Reason: Causes damage by heat transfer to the nearby carbon fiber parts
• Temperature: 1000°C
• Design Requirements :
• Light Weight,
• Reduce the temperature to 450°C
• Durable (1200km)
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4. Material SelectionPERFORMANCE
MATERIAL
COMPARISON OF MATERIALS
Mild carbon with iron oxide coating aluminized steel Stainless Steel INCONEL with Ceramic Coating
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5. Exhaust Material
• Material: heat-resistant steel called Inconel
• Inconel also called Alloy 718 contains approx
• 60% Nickel
• 22% Chromium
• Traces of Molybdenum and Niobium
• Oxidation and corrosion resistant
• Retains strength over a wide temperature range, over 1000°C.
• Thickness : 1 millimeter
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6. INCONEL 718 Alloy
http://www.imim.pl/files/archiwum/Vol4_2012/04.pdf 6

7. • Ceramics are inorganic, non-metallic materials that are processed and used at
high temperatures, highly resistant to corrosive compound, resistance to heat
and frictions (lasting longer than other materials which occurred by
machining.)
• Ceramic coatings are a special film layer used on materials to protect them
from wear and tear and to make them resistant to heat.
• Ceramic particles are sub-micron in size and consist of mixtures of selected
ceramic materials bonded together and to the substrate.
Ceramics and Ceramic Coating
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8. Ceramic Coating
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9. Temprature
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10. Coating Process
• Done by Plasma Spray Process
• Plasma spraying process involves the
latent heat of ionized inert gas (Plasma)
being used to create the heat source
• Argon flows between the electrode and
nozzle.
• A high frequency or high voltage
alternating electric arc is struck between
the nozzle and the electrode, which
ionizes the gas stream
• Due to the expansion of gas, an increase
in the velocity of gas stream.
• Feed stock (material in various powder
forms) is injected into the gas stream.
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11. Advantages
• A robust eliminating the need for exhaust wrap, protecting components against corrosion whilst continuing to
perform and look good race after race.
• Significantly lower exhaust surface temperatures (reduce by ~33%.)
• Reduced heat loss from the exhaust resulting in lower engine bay temperatures - reductions of >50oc were
recorded by one race team
• Protection for vulnerable components located close to the exhaust; avoiding heat damage, increasing
component life, and allowing closer packaging of equipment inside the engine bay.
• Improved engine performance and reliability. Lower air intake temperatures lead to increased engine
power, whilst keeping the heat inside the exhaust gas allows the gases to flow more easily increasing cylinder
scavenging, and allowing turbochargers to spool up more quickly.
• Reduced heat soak through footwells, bulkheads, etc. So drivers are potentially cooler, more comfortable, and
more able to concentrate.
• Rapid cooling of the exhaust when the engine is turned off - the surface temperature of the coating drops
quickly when the engine is off, making pit stops faster, easier and safer
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12. Comparison of Surface Temperature
Uncoated Exhaust System Ceramic coated Exhaust System
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13. Disadvantages
• Expensive
• Requires Skilled Labour
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14. Video
https://www.youtube.com/watch?v=KdsAtU3VzAM 14

15. Summary
• Ceramics counts for a good choice coating on to a heat resistant material for
better heat management system in formula one cars.
• The plasma spraying process is expensive but perfectly suitable for ceramic
coating.
• Ceramic is not only heat resistant but also corrosion resistant.
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16. References
• “Thermal barrier coatings characteristics of microstructure and properties,
generation and directions of development of bond”, by G. Moskal Department of
Materials Science, Silesian University of Technology.
• http://www.nssmc.com/en/tech/report/nsc/pdf/6403.pdf
• http://www.ijrdet.com/files/Volume2Issue3/IJRDET_0314_12.pdf
• http://www.zircotec.com/
• http://www.fst.nl/plasma-spray/
• http://www.tstcoatings.com/plasma_spray.html
• http://www.imim.pl/files/archiwum/Vol4_2012/04.pdf
• http://www.jfe-21st-cf.or.jp/chapter_1/1e_2.html
• https://www.dieselnet.com/tech/diesel_exh_mat.php
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17. Any Questions?
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18. Thank You.
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