Application of High-Precision Ultrasonic Thickness Gauges in Accurate Thickness Measurement of Aluminum-Silicon Polyester Coating Materials

Application of High-Precision Ultrasonic Thickness Gauges

 in Accurate Thickness Measurement of Aluminum-Silicon Polyester Coating Materials

Aluminum-silicon polyester coating is a composite coating technology that combines polyester resin with aluminum-silicon materials, featuring excellent properties such as high-temperature resistance, insulation, and corrosion protection.

I. Material Characteristics

High-Temperature Resistance:
The polyester-modified silicone resin can withstand temperatures above 400°C, making it suitable for use in high-temperature environments such as motors and circuit boards.

Insulation Performance:
When used as an insulating varnish, it effectively protects high-voltage equipment such as motor coils and rotor-stator assemblies.

Corrosion Resistance:
Silicone-modified polyester (SMP) coatings, enhanced by the introduction of silicone resin, significantly improve UV resistance and corrosion resistance, offering an anti-corrosion lifespan of up to 10–15 years.

II. Application Fields

Industrial Equipment:
Used for motor insulation varnish and high-temperature anti-corrosion coatings, such as silicone-based insulating varnishes capable of withstanding up to 400°C.

Architectural Decoration:
Applied in the surface treatment of color-coated aluminum or steel sheets, such as fluorocarbon polyester-coated aluminum coils, which offer both decorative appeal and corrosion resistance.

Special Environments:

In regions with sandstorms or heavy industrial pollution, silicone-modified polyester coatings provide excellent erosion resistance, effectively extending the overall service life of materials.

01. Sealing and Protection for Aircraft Engines

This coating is used as an abradable sealing layer in the compressor components of aircraft engines. By combining aluminum-silicon powder with polyester resin, it achieves precise clearance control. The coating thickness can reach up to 8 mm, with a service life exceeding 5,000 hours. It effectively reduces the friction coefficient and provides strong resistance to erosion.

02. Industrial Wear-Resistant and High-Temperature Components

Thermal Resistance:
Coatings prepared using plasma arc spraying technology can operate effectively in high-temperature environments. The island-like aluminum-silicon phase structure achieves a porosity of 10.75% with a 50% pore-forming agent content, providing both heat dissipation and weight reduction benefits.

Mechanical Properties:
Exhibiting excellent wear resistance, the coating is ideal for applications in chemical equipment, metallurgical molds, and other scenarios requiring long-term resistance to mechanical abrasion.

03. Auxiliary Materials for Semiconductor Manufacturing

In wafer production processes, aluminum-silicon polyester coatings can be applied to CMP (Chemical Mechanical Polishing) retaining rings. Their low outgassing characteristics help prevent wafer contamination while meeting the semiconductor industry's stringent requirements for dimensional stability and chemical corrosion resistance.

04. Protection in Special Environments

Chemical Stability:
Exhibits excellent resistance to acidic and alkaline media, making it suitable for use in corrosive environments such as chemical pipelines and offshore platforms.

Electrical Insulation:
With high volume resistivity, the coating serves effectively as protective insulation for electrical equipment, such as transformer winding coatings.

III. Process Comparison

Thermal Spraying:
Suitable for aluminum-silicon target materials, this process forms a dense coating by spraying molten material. Parameters such as temperature and spraying speed need to be optimized.

PVD/CVD:
Physical or chemical vapor deposition techniques can produce high-purity, uniform aluminum-silicon thin films, though the cost is relatively high.

Recently, a thermal spraying company commissioned us to inspect their aluminum-based polyester aluminum-silicon coating samples. The main requirement was to evaluate whether the coating thickness meets the design specifications.

Sample Details:
The samples are rectangular aluminum substrates with a base thickness of 7 mm and a coating thickness of 1 mm.

IV. Measurement Process

Measurement Challenge:
This highly attenuative metal coating presents a novel challenge for ultrasonic measurement techniques.

Based on the coating’s thickness range, we selected the PM5 Gen3 series ultrasonic thickness gauge. Measurement was performed using a low-frequency narrow-pulse single-crystal delay line probe. The I-E mode is ideal for measuring the thickness of highly attenuative materials, providing accurate, highly repeatable measurements with minimal error (as low as 0.003 mm).

Using the I-E mode, both the coating interface echo and the substrate echo were clearly obtained, with complete waveforms and stable measurement values, indicating good measurement performance. The D5A13 probe, a narrow-pulse, high-sensitivity probe, offers excellent resolution for highly attenuative materials, allowing clear distinction between interface and substrate echoes. The measurement results are precise and reliable.

Ultrasonic thickness gauges provide a fast, simple, and accurate method for measuring the thickness of aluminum-silicon polyester metal coatings, serving as a key tool for quality control.

Want to learn more? Contact us now to get a free trial! Choosing our high-precision ultrasonic thickness gauges means opting for professional, efficient, and reliable service. Let us safeguard your industrial operations and drive industry progress together. We look forward to cooperating with you and creating a brilliant future!