From the frying pan in the kitchen to airplanes in the sky, everything has a thin layer of coating that delivers an extra attribute that would have been impossible to achieve otherwise. These coatings can be made from different materials or applied in different ways, but they always perform better when the engineering has been pushed to its limit.
Everyday objects, from pans and pots to cars we drive around in, have a coating for a specialized function. It could be to stop food sticking or prevent fires spreading quickly. Even massive ships use special coatings to stop marine life from adhering to their hulls and increasing friction during voyages. These coatings are largely invisible, but they make life easier, safer, and more efficient.
Not just on Earth, but they also prevent astronauts from falling sick. When bacteria grow together on a surface, they secrete small molecules that form a film to help their populations thrive. These films, known as biofilms, can contain toxins that prevent other organisms from growing and make humans extremely sick if ingested.
In low-gravity environments such as spacecraft, bacteria grow at an accelerated pace, and so do biofilms. Left unchecked, these films can contaminate water supplies and, in worst-case scenarios, they can also cause mechanical failures, risking astronaut health and safety.
A research team led by Kripa Varanasi, a professor of mechanical engineering at the Massachusetts Institute of Technology (MIT), has developed a slippery coating using solid materials and a lubricant that prevents biofilm formation in spacecraft. This was tested on the International Space Station (ISS) in an experiment a few years ago.
Interestingly, a similarly slippery coating helps remove the last ounce of toothpaste from the tube. Varanasi's company also provides the coating for that, saving you pennies every month.
Nearly a century ago, the jet engine was invented, but without specialized coatings, it wouldn't fly around as easily as it does today. The principle behind a jet is simple, but the actual engineering can be complicated. Hot air from the engine's exhaust often reaches temperatures above 1,832 Fahrenheit (1,000 degrees Celsius). At these temperatures, the engine's metal should melt, shutting down operations. However, a ceramic coating on the metal allows it to continue operation.
Researchers are now working on improving the coating. Just a 30 degree Celsius increase in temperatures inside the engine can deliver eight percent of fuel savings, reducing costs and carbon emissions simultaneously, a BBC report said.
A UK-based company is developing coatings for moving components in satellites. The challenge is tougher because the coatings need to withstand normal atmospheric conditions during pre-launch and intense radiation and dust particles when in orbit.
A slippery coating made from silicon carbide is helping companies save millions every year. Large-scale and powerful industrial machinery is prone to wear and tear. However, in the case of aluminum manufacturing and repair, this can demand retooling every two days.
A US-based machine and supply firm spent $4.5 million a year rebuilding its roller tools to work with aluminum. With a coating, the tool needs rebuilding only once a week, and costs have shrunk to less than a third now, the BBC report added.
Yet, we haven't fully explored this area, and much remains to be discovered and applied. When engineering seems to hit its limits, coatings always manage to deliver a way out.
