{"id":3109,"date":"2026-09-14T12:01:26","date_gmt":"2026-09-14T10:01:26","guid":{"rendered":"https:\/\/www.buser-ot.ch\/?page_id=3109"},"modified":"2026-09-14T12:39:40","modified_gmt":"2026-09-14T10:39:40","slug":"ceramic-coating","status":"publish","type":"page","link":"https:\/\/www.buser-ot.ch\/en\/usage-fuctions\/ceramic-coating\/","title":{"rendered":"Ceramic Coating"},"content":{"rendered":"
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Ceramic Coating: Durable Surfaces for Technical Components<\/h1>\n\n<\/div>\n\n\t<\/div>\n\n<\/div>\t\t\n\n\n\n\n\n
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Ceramic coatings impart specific properties to components that the base material alone cannot provide, or can provide only to a limited extent. Depending on the ceramic used, they protect surfaces from wear, high temperatures, electrical voltage, or aggressive process conditions. At the same time, the structural integrity of the metal substrate is preserved.<\/p>\n\n\n\n

We coat individual parts and mass-produced components with various oxide ceramics and tailor the material, coating structure, and post-processing to the specific application. This results in functional surfaces for mechanical and plant engineering, energy and electrical engineering, metal processing, and numerous other industrial sectors.<\/p>\n\n\n\n

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Contact us now for a consultation!<\/a><\/div>\n<\/div>\n\n\n\n
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What is a ceramic coating?<\/h2>\n\n\n\n

In a ceramic coating, a ceramic material is applied to the surface of an existing component. Metals such as steel, stainless steel, aluminum, or suitable alloys often serve as the substrate. The component thus retains its mechanical strength but gains the desired properties of the ceramic on its surface.<\/p>\n\n\n\n

Unlike a component made entirely of ceramic, the entire component does not have to consist of a hard but comparatively brittle material. Instead, the ceramic can be applied specifically where it is actually needed.<\/p>\n\n\n\n

However, the term \u201cceramic coating\u201d is used for various coating systems. The following distinctions are particularly important:<\/p>\n\n\n\n

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  1. thermally sprayed oxide ceramics <\/strong>for wear protection<\/a>, insulation, and high temperatures,<\/li>\n\n\n\n
  2. thin sol-gel coatings for properties such as easy-to-clean, anti-fog, or wetting characteristics,<\/li>\n\n\n\n
  3. ceramic-filled paints and composite coatings,<\/li>\n\n\n\n
  4. polymer-based powder coatings applied to a ceramic substrate.<\/li>\n<\/ol>\n\n\n\n

    Thermally sprayed oxide ceramics are primarily used for particularly hard and technically robust ceramic coatings.<\/p>\n\n\n\n

    Properties and Advantages of Ceramic Coatings<\/h2>\n\n\n\n

    The properties of a ceramic coating depend on the material used, the coating process, the coating thickness, and the overall coating structure. Through application-specific design, different functions can be achieved or combined:<\/p>\n\n\n\n

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    1. Wear and abrasion protection: <\/strong>The high hardness of ceramic materials protects running, guide, sliding, and sealing surfaces from abrasive stress.<\/li>\n\n\n\n
    2. Electrical insulation: <\/strong>Certain oxide ceramics have high electrical resistance and enable insulating surfaces on metallic components.<\/li>\n\n\n\n
    3. Thermal insulation: <\/strong>Ceramic coatings with low thermal conductivity reduce heat transfer into the base material.<\/li>\n\n\n\n
    4. Temperature resistance: <\/strong>Suitable ceramic systems can be used even at high operating and surface temperatures.<\/li>\n\n\n\n
    5. Chemical resistance: <\/strong>Depending on the type of ceramic, the coatings resist various process media and corrosive influences.<\/li>\n\n\n\n
    6. Reduced wettability: <\/strong>Certain ceramics are poorly wetted by liquid metals and are therefore suitable for applications in melting and casting technology.<\/li>\n\n\n\n
    7. Longer service life: <\/strong>Protected surfaces wear more slowly, which can extend maintenance intervals and reduce downtime.<\/li>\n<\/ol>\n\n\n\n

      Ceramic coatings are suitable for both new components and the refurbishment of high-quality components. In many cases, worn-out parts or damaged functional surfaces can be restored without having to replace the entire component.<\/p>\n\n\n\n

      Applying Ceramic Coatings via Thermal Spraying<\/h2>\n\n\n\n

      Oxide ceramics have very high melting temperatures. Atmospheric plasma spraying is therefore predominantly used to apply them. This process is a form of thermal spraying<\/a> and enables the deposition of durable ceramic coatings on metallic substrates.<\/p>\n\n\n\n

      In plasma spraying, a process gas is intensely heated and ionized by an electric arc. Ceramic powder is introduced into the resulting high-energy plasma jet. The powder particles are melted or partially melted, accelerated , and propelled onto the prepared component surface. There, they solidify and gradually form the desired coating.<\/p>\n\n\n\n

      The component itself is not completely melted during this process. The thermal stress on the substrate therefore remains significantly lower than in many fusion metallurgical processes. Nevertheless, the material, component geometry, and potential warping must be taken into account as early as the planning stage.<\/p>\n\n\n\n

      Depending on the application, the layer structure may comprise several levels:<\/p>\n\n\n\n

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      1. The base material is cleaned and roughened to a specified degree.<\/li>\n\n\n\n
      2. If necessary, a metallic bonding or intermediate layer is applied.<\/li>\n\n\n\n
      3. The ceramic functional layer is built up step by step.<\/li>\n\n\n\n
      4. Pores can then be sealed with a suitable sealing agent.<\/li>\n\n\n\n
      5. The surface is finished to the desired dimensions and required roughness.<\/li>\n<\/ol>\n\n\n\n

        By combining different materials, adhesion, temperature resistance, wear protection, and other properties can be specifically tailored to one another.<\/p>\n\n\n\n

        Ceramic Materials and Their Respective Advantages<\/h2>\n\n\n\n

        Not every ceramic is suitable for the same loads. We process various oxide ceramics based on aluminum, chromium, titanium, and zirconium, as well as tailored mixtures of these materials. The selection depends on the required surface function.<\/p>\n\n\n\n

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        1. Aluminum oxide, <\/strong>Al\u2082O\u2083: <\/strong>Aluminum oxide is characterized by high hardness, good wear resistance, and excellent electrical insulation properties. It is used, among other things, for bearing seats, guides, rollers, and insulating functional surfaces.<\/li>\n\n\n\n
        2. Chromium oxide, <\/strong>Cr\u2082O\u2083: <\/strong>Chromium oxide forms particularly hard and abrasion-resistant coatings. It also offers good chemical resistance and is suitable for heavily stressed sealing, running, and guide surfaces.<\/li>\n\n\n\n
        3. Titanium oxide, <\/strong>TiO\u2082: <\/strong>Titanium oxide enables comparatively dense ceramic coatings and is frequently used for sliding or surfaces requiring post-processing.<\/li>\n\n\n\n
        4. Aluminum oxide\u2013titanium oxide mixtures: <\/strong>By combining both oxides, hardness, toughness, and wear behavior can be tailored to the specific application.<\/li>\n\n\n\n
        5. Zirconia, <\/strong>ZrO\u2082: <\/strong>Zirconia has low thermal conductivity and is particularly suitable for heat-insulating coatings and thermally stressed components.<\/li>\n\n\n\n
        6. Other composite ceramics: <\/strong>Different oxides can be combined to specifically influence properties such as friction behavior, density, thermal shock resistance, or machinability.<\/li>\n<\/ol>\n\n\n\n

          Therefore, the most technically and economically suitable ceramic cannot be determined solely on the basis of a general materials table. The actual operating conditions of the component are decisive.<\/p>\n\n\n\n

          Heat-Resistant Ceramic Coatings for High-Temperature Applications<\/h2>\n\n\n\n

          A heat-resistant ceramic coating can protect the base material from direct heat exposure and reduce heat flow through the component. In particular, zirconia and multi-layer systems tailored to it are used as thermal barriers.<\/p>\n\n\n\n

          Possible applications include the energy, furnace, turbine, exhaust gas, and process engineering sectors<\/strong>. Ceramic thermal insulation layers can, for example, help protect metallic components from excessively high surface temperatures or retain heat specifically within the process area.<\/p>\n\n\n\n

          However, the suitability of a high-temperature ceramic coating does not depend solely on a maximum temperature rating.<\/p>\n\n\n\n

          In the design process, we take the following factors into account, among others:<\/p>\n\n\n\n

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          1. the continuous operating temperature,<\/li>\n\n\n\n
          2. short-term temperature spikes,<\/li>\n\n\n\n
          3. the rate of heating and cooling,<\/li>\n\n\n\n
          4. frequent temperature cycles,<\/li>\n\n\n\n
          5. the thermal expansion of the base material,<\/li>\n\n\n\n
          6. possible oxidation or corrosion beneath the ceramic layer,<\/li>\n\n\n\n
          7. mechanical stresses during operation.<\/li>\n<\/ol>\n\n\n\n

            A constantly high temperature may be less critical for a coating system than frequent and rapid fluctuations between <\/strong>hot <\/strong>and cold. <\/strong>For this reason, the appropriate ceramic coating is always selected based on the specific application and not merely on a general temperature limit.<\/p>\n\n\n\n

            Typical Applications of Ceramic Coatings<\/h2>\n\n\n\n

            Ceramic coatings are suitable wherever metallic surfaces are exposed to particularly high functional stresses.<\/p>\n\n\n\n

            Typical areas of application include:<\/p>\n\n\n\n

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            1. Machinery and plant engineering,<\/li>\n\n\n\n
            2. pump, valve, and sealing technology,<\/li>\n\n\n\n
            3. textile, paper, and printing industries,<\/li>\n\n\n\n
            4. Electrical and insulation technology,<\/li>\n\n\n\n
            5. Energy and power plant technology,<\/li>\n\n\n\n
            6. Metal processing and smelting technology,<\/li>\n\n\n\n
            7. chemical and process engineering plants,<\/li>\n\n\n\n
            8. furnace and high-temperature technology.<\/li>\n<\/ol>\n\n\n\n

              Examples of components that can be coated include shafts, rollers, bearings, pistons, guides, sliding elements, and sealing surfaces. Areas requiring electrical insulation, thermally stressed components, or components in contact with abrasive media can also be specifically protected.<\/p>\n\n\n\n

              The coating can cover either the entire accessible surface or a clearly defined functional area. Surfaces, threads, bores, and fits that are not to be coated are covered accordingly during the process.<\/p>\n\n\n\n

              The Process of Professional Ceramic Coating<\/h2>\n\n\n\n

              To ensure that a ceramic coating fulfills its function over the long term, the base material, preparation, coating process, and post-processing must be precisely coordinated.<\/p>\n\n\n\n

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              1. \n Analyze Requirements:<\/strong>\n First, the actual operating conditions are assessed. These include the type of wear, temperature, process media, electrical requirements, desired coating thickness, and required surface quality. Existing damage and the component\u2019s design are also taken into account.\n <\/li>\n\n
              2. \n Selecting the Material and Coating System:<\/strong>\n Based on the requirements, we determine the appropriate ceramic, a potential bonding layer, and the necessary coating structure. If necessary, different materials are combined into a functional multilayer system.\n <\/li>\n\n
              3. \n Preparing the Component:<\/strong>\n The surface is thoroughly cleaned and freed of oxides, greases, or other contaminants. Areas not to be coated are masked off. The coating surface is then roughened in a controlled manner so that the sprayed particles can mechanically anchor themselves.\n <\/li>\n\n
              4. \n Applying the Ceramic Coating:<\/strong>\n The ceramic powder is applied via plasma spraying in several passes. This allows the coating to be built up in a controlled manner to the intended thickness.\n <\/li>\n\n
              5. \n Post-treatment of the Coating:<\/strong>\n Depending on the application, the ceramic coating is sealed, ground, lapped, or polished. This ensures precise dimensions, fits, and surface roughness.\n <\/li>\n\n
              6. \n Quality Control:<\/strong>\n Finally, the agreed-upon characteristics are inspected. These may include, for example, coating thickness, dimensional accuracy, roughness, surface finish, and adhesion.\n <\/li>\n<\/ol>\n\n\n\n

                Thanks to our capabilities in surface finishing and mechanical post-processing<\/a>, we can coordinate the coating and final finishing processes.<\/p>\n\n\n\n

                Ceramic powder coating or ceramic coating?<\/h2>\n\n\n\n

                The term \u201cceramic powder coating\u201d can have different meanings. In classic powder coating, a polymer-based powder coating is applied electrostatically and then cured. The result is a plastic coating, even if the coated component itself is made of ceramic.<\/p>\n\n\n\n

                In contrast, thermal ceramic coating involves the use of genuine ceramic powders. Since oxide ceramics have very high melting temperatures, a conventional powder coating process is not sufficient for this purpose. Instead, the powder is heated in a plasma jet and applied at high speed to the prepared surface.<\/p>\n\n\n\n

                Which solution is appropriate depends on the desired function:<\/p>\n\n\n\n

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                1. For high hardness, abrasion resistance, or electrical insulation, a thermally sprayed oxide ceramic is often the best choice.<\/li>\n\n\n\n
                2. For decorative or polymer-based protective coatings, powder coating may be an option.<\/li>\n\n\n\n
                3. For very thin \u201ceasy-to-clean,\u201d wetting, or anti-fingerprint surfaces, sol-gel systems may be more suitable.<\/li>\n\n\n\n
                4. For complex loads, combination coatings made of multiple materials may be necessary under certain circumstances.<\/li>\n<\/ol>\n\n\n\n

                  Therefore, what matters is not the general designation, but the specific requirements profile of the surface.<\/p>\n\n\n\n

                  What to Consider with Ceramic Coatings<\/h2>\n\n\n\n

                  Ceramic coatings offer exceptional hardness and durability, but they also have material-specific limitations. These must be taken into account during design and specification.<\/p>\n\n\n\n

                  Ceramics are hard but less ductile than metal. Severe impacts, localized stresses, or deformation of the substrate can therefore lead to cracks or spalling. In such applications, it must be determined whether a tougher composite ceramic, an adjusted coating thickness, or an alternative coating system is more suitable.<\/p>\n\n\n\n

                  Thermally sprayed ceramic coatings also exhibit a certain degree of porosity due to the nature of the process. Additional sealing may be required in cases of contact with liquids, corrosive media, or when high levels of leak tightness are required.<\/p>\n\n\n\n

                  Other important criteria include:<\/p>\n\n\n\n

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                  1. Accessibility of the surface to be coated,<\/li>\n\n\n\n
                  2. edges, holes, and undercuts,<\/li>\n\n\n\n
                  3. required coating thickness,<\/li>\n\n\n\n
                  4. mechanical stress on the substrate,<\/li>\n\n\n\n
                  5. possible temperature fluctuations,<\/li>\n\n\n\n
                  6. required dimensional and geometric tolerances,<\/li>\n\n\n\n
                  7. desired surface roughness,<\/li>\n\n\n\n
                  8. type of subsequent finishing.<\/li>\n<\/ol>\n\n\n\n

                    Particularly for fits, bearing seats, and sealing surfaces, it should be determined before coating which dimensions must be achieved after grinding or polishing. Early coordination prevents unnecessary machining steps and improves the technical reliability of the entire coating system.<\/p>\n\n\n\n

                    Have Custom Ceramic Coatings Custom-Made at Buser<\/h2>\n\n\n\n

                    Whether for wear protection, electrical insulation, or thermal barriers: a ceramic coating only fully realizes its benefits when it is precisely tailored to the component and its operating conditions.<\/p>\n\n\n\n

                    We offer a wide selection of sprayable oxide ceramics and use them to develop custom-tailored single and combination coatings<\/strong>. We support you every step of the way\u2014from selecting the appropriate material, through sample production and test coatings, to final mechanical finishing.<\/p>\n\n\n\n

                    We can also repair and restore worn components. This allows high-quality components to be used longer, reduces replacement part costs, and improves the functionality of existing designs.<\/p>\n\n\n\n

                    Send us your drawing, details about the base material, and the key operating conditions. Together, we\u2019ll determine which ceramic coating makes the most technical and economic sense for your application.<\/p>\n\n\n\n

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                    Contact us now for a consultation!<\/a><\/div>\n<\/div>\n\n\n\n
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                    FAQ: Frequently Asked Questions About Ceramic Coatings<\/h2>\n\n\n\n

                    What are the advantages of ceramic coatings?<\/h3>\n\n\n\n

                    Among other things, they can reduce wear, provide electrical insulation, insulate against heat, and increase resistance to high temperatures or certain process media.<\/p>\n\n\n\n

                    Which components can be coated with ceramics?<\/h3>\n\n\n\n

                    Examples of components that can be coated include shafts, rollers, bearings, guides, sealing surfaces, pump components, and machine parts subjected to thermal stress.<\/p>\n\n\n\n

                    What ceramic materials are used?<\/h3>\n\n\n\n

                    Typical materials include aluminum oxide, chromium oxide, titanium oxide, zirconium oxide, and various composite ceramics.<\/p>\n\n\n\n

                    Are ceramic coatings heat-resistant?<\/h3>\n\n\n\n

                    Yes. However, the actual temperature resistance depends on the ceramic material, the coating structure, the base material, and the temperature fluctuations that occur.<\/p>\n\n\n\n

                    Can ceramic coatings provide electrical insulation?<\/h3>\n\n\n\n

                    Yes. Aluminum oxide, in particular, is suitable for electrically insulating functional coatings on metallic components.<\/p>\n\n\n\n

                    Are ceramic coatings waterproof?<\/h3>\n\n\n\n

                    Thermally sprayed ceramic coatings may exhibit a certain degree of porosity. If high levels of impermeability are required, an additional sealant may be necessary.<\/p>\n\n\n\n

                    How is the appropriate ceramic coating selected?<\/h3>\n\n\n\n

                    Key factors include the type of wear, temperature, process media, electrical requirements, component geometry, and desired surface quality.<\/p>\n\n\n\n