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Dielectric Coatings

Dielectric coatings are used for high and low voltage applications over the range of DC to RF. With the ability of thermal spray to apply an almost limitless number of materials, a well-engineered dielectric coating can be produced to solve even some of the most complex electrical problems. Dielectric strengths for ceramic coatings range from 350 to over 1000 volts per mil, as a function of thermal spray process and parameters.

When engineering a dielectric coating Thermal Spray Technologies uses its strong expertise in materials engineering and its strength of understanding of the processes of thermal spray and electrical phenomena. The combination of this knowledge provides application specific solutions to our customers' electrical problems.

Coating Materials

The most commonly used thermal spray dielectric materials are oxide ceramics and polymers. Ceramics are more durable, wear and corrosion resistant, and have higher dielectric strengths than polymers. Common materials include oxides of aluminum, titanium, and yttrium. Other materials, alloys, and compounds are used as well.

Substrate Materials

There are few, if any, limitations to the substrate materials. Typically, dielectric coatings are applied to metallic substrates, however, composite structures can also be coated. Where the application for a dielectric coating involves high temperatures, gradated coatings are employed to mitigate differential expansion between the substrate and the dielectric coating.

Examples

Practical uses for dielectric coatings includes semiconductor heat sinks, electro-surgical instruments, corona treater rolls for printing, corona suppression in high voltage systems (including PVD processing), application of high-temperature strain gages, fabrication of thermal spray resistance heaters, as substrates for sprayed electrical conductors, free-standing electrical insulators such as laser wave guides, etc.

Bi-polar electrical surgical device coated with dielectric coating