Development of coatings on titanium alloys for protection against high-temperature oxidation in the automotive industry

This thesis explores the characteristics, manufacturing methods, and applications of titanium, with a focus on its surface protection against high-temperature oxidation. In Uzbekistan, the growing interest in sports cars and racing has increased the demand for advanced automotive technologies. One significant challenge is the overheating of exhaust systems, particularly in vehicles using nitrous oxide ("nitro"), which can lead to reduced efficiency, safety risks, and potential damage. This research investigates material enhancements and protective coatings to improve oxidation resistance and thermal stability. The first section reviews titanium metallurgy, including its crystal structure, phase transitions, and alloy classifications, as well as its physical, mechanical, and chemical properties. It discusses conventional and advanced machining methods and examines various surface protection techniques—such as silicon, aluminum, and glass-ceramic coatings—to combat oxidation. The second section addresses adhesion theories and coating application mechanisms, including mechanical interlocking and chemical adsorption. It evaluates coating deposition methods, causes of failure, and factors influencing adhesion strength, focusing on titanium coatings for harsh environments. Experimental titanium samples underwent cutting, polishing, and contamination removal to enhance adhesion, with comparative data collected from glass substrates. Coatings were applied under controlled conditions, followed by heat treatments to improve stability and microstructural integrity. A prototype titanium component was developed to demonstrate practical viability. Characterization techniques and analysis including metallographic microscopy, thermal shock resistance assessments, SEM, FTIR, EDS, and XRD, were employed to evaluate adhesion quality, thickness uniformity, and surface roughness. Results indicate that titanium coatings significantly enhance thermal management and durability, offering solutions to overheating issues in sports car exhaust systems. These findings are vital for mitigating overheating in high-performance exhaust systems, as material enhancements can lower thermal stress and oxidation rates, thereby extending component lifespan. By utilizing advancements in titanium coating research, the automotive industry can develop innovative exhaust designs that improve safety and promote sustainable high-performance vehicles. Future research should prioritize customizing coatings for extreme combustion conditions to ensure reliability during nitro-boosted operations.