Next-generation formulation supports lightweighting drive for motorsport teams and manufacturers
Zircotec, the trusted thermal management partner to teams in Formula One and other elite motorsport championships, has engineered a new formulation of its plasma-applied ceramic coating technology for composites materials that is 69% lighter than its predecessor.
The Oxfordshire-based company’s patented ThermoHold® for Composites product contains a proprietary blend of Zirconia-based ceramics and is applied to lightweight carbon composite materials to provide an ultra-high performance thermal barrier and to protect vulnerable surfaces from wear and abrasion on the race track.
This technology allows teams and manufacturers across multiple motorsport categories to use lightweight composite materials in environments where they would ordinarily be damaged by exposure to heat if left unprotected. Typical applications include composite brake duct componentry, heat shields, suspension and bodywork.
The latest breakthrough by the Zircotec Research and Development team has unlocked a 69% weight saving in its latest-generation ThermoHold® for Composites product, meaning the coating now weighs only 0.042g per cm2 (or 420g per m2 of coated area). This has been achieved without any loss of thermal or mechanical performance.
“Performance and success in motorsport is largely driven by lightweighting, so we’re thrilled with the results of our latest ThermoHold® for Composites R&D project,” Dominic Graham, Zircotec Engineering Director, explained.
“Formulating a coating that is 69% lighter is a huge upgrade and gives teams across the motorsport spectrum a valuable opportunity to save a significant amount of weight – while maintaining all of the same market-leading thermal barrier and physical performance properties they currently enjoy through Zircotec’s patented technology.”
Richard Carter, Zircotec Head of Motorsport, added: “By re-configuring our plasma spraying parameters, we’ve unlocked a game-changing ThermoHold® for Composites formulation that will withstand temperatures of up to 1400°C, provides ~80% reflectivity, is less than 200μm thick, and weighs only 0.042g per cm2.
“This latest coating represents a significant material lightweighting boost for motorsport teams and manufacturers – helping them to secure a competitive edge in a critical area of development.”