In the power generation industry, gas turbines are under constant pressure to deliver higher efficiency and lower emissions. This push for performance leads to ever-increasing combustion temperatures, often reaching 1200 to 1300°C, which poses a critical challenge: how to protect metal components operating in extreme thermal conditions.
This introduces several key challenges:
- Thermal stress & Component degradation : Higher temperatures reduce efficiency of traditional metal parts, accelerating oxidation, erosion and thermal fatigue.
- Cycle life & Maintenance : Turbine components must endure rapid heating and cooling cycles while maintaining structural integrity over time.
- Efficiency demands : applicators need thermal barrier coatings (TBCs) that improve heat resistance without compromising cost or production efficiency.
WHY CHOOSE SAINT-GOBAIN COATING SOLUTIONS
We are a global leader in advanced zirconia-based materials, trusted by major OEMs and applicators in the energy sector worldwide.
- Proven TBC Expertise : Rooted in decades of zirconia formulation experience (from the Norton heritage), we deliver coatings engineered to meet the mechanical, thermal, and durability requirements of land-based gas turbines.
- Power Generation-Focused R&D : Our powders are validated under real-world turbine operating conditions. Each formulation is optimized to balance thermal insulation, erosion resistance, and deposition efficiency — ensuring longer uptime and lower maintenance.
- End-to-End Process Mastery : From powder behavior to spray parameters, our team ensures reliable, repeatable coating performance, across facilities, equipment, and spray technologies.
- Global Reach with Local Support : With a footprint across five continents, we provide fast technical support, logistics coordination, and tailored guidance for power generation and maintenance customers worldwide.
OUR SOLUTIONS: ZIRCONIA-BASED TBC POWDERS
Zirconia-based coatings are the standard choice for gas turbines due to their excellent thermal insulation. Since pure zirconia is unstable at high temperatures, it must be chemically stabilized (with yttria, calcia, ceria, etc.) to ensure phase stability and durability under thermal cycling. Our formulations are optimized to deliver the right balance of insulation, erosion resistance, and long-term performance.
Our core product families include:
- 8% Yttria-Stabilized Zirconia (8YSZ)
- 20% Yttria-Stabilized Zirconia (20YSZ)
- Magnesium Zirconate
- Ceria-Stabilized Zirconia
- Calcia-Stabilized Zirconia
#204 / #204PR / #204F
This industry-standard TBC material is stable up to 1300 °C and widely qualified by major OEMs. It offers high deposit efficiency with strong resistance to thermal shock, erosion, and corrosion. Low monoclinic content supports phase stability and long coating life — ideal for turbine hot sections and other demanding high-temperature applications.
→ View the full powder selection guide here
#202
Designed for maximum thermal insulation (stable up to 1500 °C), 20YSZ offers lower thermal conductivity and better corrosion résistance than 8YSZ. Its softer structure makes it easier to machine, but slightly less erosion-resistant, best suited for static parts in base-load turbines.
Hollow spherical particles provide high spray efficiency and consistent coating quality in demanding thermal environments.
#233
A fused and crushed powder with irregular morphology, Magnesium Zirconate is engineered for thermal shock resistance and particle erosion protection at temperatures up to 1500 °C. It forms stable, porous coatings ideal for older turbine designs, diesel engines, molten metal tooling, and exhaust systems.
#234 / #253
This fused and crushed zirconia, stabilized with ceria, provides excellent thermal stability and resistance to phase transformation under thermal cycling. Its irregular morphology and tough microstructure help reduce crack propagation, extending coating life in turbine hot sections and other high-temperature environments.
Best suited for components exposed to fluctuating thermal loads where both insulation and mechanical durability are critical.
#235 / #252
This fused and crushed zirconia, stabilized with 5% calcia, offers good thermal shock resistance and long-term durability in high-temperature environments. Its irregular morphology makes it suitable for older turbine designs, steel furnace components, and thermal barrier coatings where abrasion resistance is also important.
Low monoclinic content improves phase stability under thermal cycling. Often used in non-engine TBC applications or steel industry parts.
Custom chemistries available on request: rare-earth doping, special PSDs, etc.
Need Help Selecting the Right Powder?
We can help you identify the ideal TBC powder for your turbine system based on: operating temperature, component geometry, erosion/corrosion environment or spray process parameters.
