Benchtop Spray Pyrolysis for Preceramic Polymers

Benchtop Spray Pyrolysis of Preceramic Polymers for Complex Ceramics

This study introduces a transformative and rapid approach for synthesizing compositionally complex ceramic coatings from preceramic polymers and metal precursors. The resulting ceramics exhibit a distinctive combination of high emissivity, low electrical resistivity, exceptional oxidation resistance, and mechanical robustness, rendering them highly suitable for extreme environments in aerospace, electronics, and energy applications.

A key innovation lies in the capability for air sintering within seconds—significantly simplifying traditional processing that typically requires high temperatures and inert atmospheres. This is achieved through a compositionally tunable system based on polymer-derived ceramics, incorporating multiple metallic precursors and passive fillers to confer both protective and functional characteristics.

Beyond synthesis, this work demonstrates precise engineering and spatial control of metallic phases within the ceramic matrix. Such control not only enhances structural integrity and thermal shock resistance but also enables performance customization for specific applications. Importantly, the conversion process dispenses with the need for sintering aids or external pressure, facilitating scalable deposition even on non-planar and thermally sensitive substrates.

The performance of these coatings is rigorously validated under high-flux oxygen–hydrogen torch testing, where they effectively inhibit oxidation of underlying copper at surface temperatures exceeding 1,300 K. Moreover, post-conversion resistivity measurements offer a practical metric for assessing ceramic transformation quality and coating uniformity.

This work establishes a new paradigm in ceramic coating technology: multifunctional, rapidly processable, and environmentally resilient. The ambient-air compatibility of the method—adaptable to diverse metal systems—opens pathways to on-demand and site-specific fabrication of advanced ceramics. It not only redefines how these materials are manufactured but also vastly expands their potential deployment scenarios, pushing the boundaries of material performance in demanding operational domains.

About Cheersonic

Cheersonic is the leading developer and manufacturer of ultrasonic coating systems for applying precise, thin film coatings to protect, strengthen or smooth surfaces on parts and components for the microelectronics/electronics, alternative energy, medical and industrial markets, including specialized glass applications in construction and automotive.

Our coating solutions are environmentally-friendly, efficient and highly reliable, and enable dramatic reductions in overspray, savings in raw material, water and energy usage and provide improved process repeatability, transfer efficiency, high uniformity and reduced emissions.

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