Thermal spray engine coatings: Solve common problems with engines

The development of engine coatings

There are an estimated 2 billion combustion engines being used worldwide. Whilst many manufacturers are turning their attention to the advancement of electric vehicle technology, there are some manufacturers who understand that the internal combustion engine will remain in service for a long time to come. They are working hard to further develop existing engine technology, allowing its continued use whilst meeting the ever more stringent demands of environmental legislation. Through the use of thermal spray engine coatings, manufacturers have been able to improve the functionality of vehicles all over the world.

How can thermal spray coatings be used to solve engine problems?

Thermal spray coatings are thin layers of material that are deposited onto a component using a thermal spray process. The process typically involves heating a material and accelerating it towards a component, using a flame, plasma or electric arc. Vehicle manufacturers have found that this process can be used to create solutions for some of the most common engine problems.


Engine corrosion can occur for many reasons. However, the most common reason for engine corrosion is sulphuric acid. In both petrol and diesel, sulphur is a naturally occurring component. During combustion, this sulphur forms sulphuric acid which can cause corrosive wear to metal surfaces. Corrosion can have a significant impact on both the efficiency and longevity of the engine, leading to increased service costs and lower fuel efficiency.

Thermal spray coatings can be used to enhance and protect existing engine components. Allowing them to not only withstand attack from conventional fossil fuel based combustion, but also allowing for the use of newer “Green” fuels within existing engines, meaning that already costly units can be converted rather than replaced.

Turbo Charger Improvement

EPC has worked with several manufacturers, helping to develop thermal spray coating applications that allow for tighter impeller / housing clearances, leading to significant improvement in fuel consumption and overall engine performance.

Exhaust Gas Corrosion

With the ever increasing focus on engine emission control and fuel economy, multiple solutions are being designed for use within the engine exhaust system. Thermal spray coatings have been successfully used to allow critical components to operate effectively whilst sitting directly in the exhaust gas stream, dealing with temperatures in excess of 600 degrees centigrade, whilst withstanding the multiple corrosive compounds that are ever present.


Find a solution to common engine problems

EPC specialises in the development of thermal spray coatings and have been involved in several successful projects to date. We have a team of technical experts, who will take the time to understand the problem you are attempting to overcome, whilst also understanding the ever present pressures of cost control and repeatability expectations within your industry.

To find out more about our thermal spray coatings for combustion engines, get in touch.