Abrasion and Wear Protection

Precision Cerakote ceramic coatings for aerospace, defense, and industrial components.

The cost

What Happens When Wear Goes Unchecked

Moving parts, abrasive particles, handling impacts, and chemical exposure degrade unprotected surfaces in every operating cycle. Sand, dust, and grit score metal. Repeated contact strips material away. By the time wear becomes visible, the part has already moved out of tolerance and compromised the system around it.

  • Unplanned downtime: Worn components force equipment offline for inspection and replacement, costing thousands per hour in production environments
  • Accelerating failure: Surface damage exposes base material to corrosion and chemical attack, compounding the original wear damage
  • Tolerance loss: Abrasion removes material from precision surfaces, pushing parts beyond dimensional limits and triggering scrap or rework
Cerakote spray application wide angle at ColoradoKote
Multi-part Cerakote coating setup at ColoradoKote
The answer

How Ceramic Coating Defeats Surface Wear

Cerakote® creates a ceramic-polymer matrix that bonds at the molecular level with the substrate. The ceramic particles deliver 9H pencil hardness, the maximum on the ASTM D3363 scale, while the polymer matrix absorbs impact energy without cracking. The result is a coating that is hard enough to resist abrasion yet flexible enough to survive mechanical shock.

  • Abrasion resistance: 8,000+ wear cycles per mil (ASTM D4060), outperforming Teflon coatings by more than 8 to 1 in standardized Taber testing
  • Impact strength: 160/160 in-lbs direct and reverse impact (ASTM D2794) with no cracking or delamination, unlike hard anodizing which fractures under shock
  • Low friction: Elite Series achieves a coefficient of friction of approximately 0.11, rivaling Teflon dry lubricity while maintaining superior hardness and wear life

Tested and Verified Wear Performance

Every wear performance claim is verified through independent laboratory testing per ASTM standards. Results are documented under AS9100:2015 quality controls with full traceability from raw material to finished part. Test reports are available for download upon request.

  • Pencil hardness (ASTM D3363): 9H, the maximum rating on the scale, exceeding Type III hard anodizing at 7H-8H and powder coating at 4H-6H
  • Impact resistance (ASTM D2794): 160/160 in-lbs with zero cracking or delamination, more than double the 20-40 in-lbs typical of aerospace paint systems
  • Taber abrasion (ASTM D4060): 8,000+ wear cycles per mil, verified against Teflon coatings at under 1,000 cycles under identical test conditions
  • Flexibility (ASTM D522): 180-degree mandrel bend with 0 mm coating loss, proving the coating resists wear without becoming brittle
  • Certification stack: AS9100:2015, ISO 9001:2015, ITAR registered, and Cerakote® Advanced Applicator, the highest tier from NIC Industries held by fewer than 5% of applicators
Fresh Cerakote coating inspection at ColoradoKote
Industries

Industries That Need Wear Protection

Abrasion-resistant ceramic coating for high-wear components.

Cerakote coating consistency check at ColoradoKote

Weight Reduction for Oil and Gas Equipment

Thick coatings add mass to equipment transported to remote wellsites and offshore platforms. Cerakote at 0.5-2 mils saves 200-400g per part versus powder coating. ISO 9001 certified.

Cerakote coating consistency check at ColoradoKote

Weight Reduction for Medical Device Components

Surgical instruments must be light enough for hours of precise use. Cerakote at 0.5-2 mils saves 200-400g per part versus powder coating without compromising protection. ISO 9001 certified.

Cerakote coating consistency check at ColoradoKote

Weight Reduction for Maritime Equipment

Heavy coatings add mass to marine hardware that affects vessel performance and handling. Cerakote at 0.5-2 mils saves 200-400g per part versus powder coating. ISO 9001 certified.

Cerakote coating consistency check at ColoradoKote

Weight Reduction for Industrial OEM Components

Thick coatings add unnecessary mass to engineered equipment. Cerakote at 0.5-2 mils delivers 200-400g savings per part versus powder coating while preserving tolerances. ISO 9001 certified.

Cerakote coating consistency check at ColoradoKote

Weight Reduction for Defense and Tactical Equipment

Tactical systems carry weight penalties from thick coatings that reduce mobility and increase operator fatigue. Cerakote at 0.5-2 mils saves 200-400g per part. ITAR registered, AS9100 certified.

Cerakote coating consistency check at ColoradoKote

Weight Reduction for Automotive R&D Prototypes

Every 100 lbs of EV mass costs 2-3 percent range. Cerakote at 0.5-2 mils saves 200-400g per part versus powder coating, protecting prototypes without adding mass. ISO 9001 certified.

Cerakote coating consistency check at ColoradoKote

Weight Reduction for Agriculture Equipment

Heavy coatings add mass to field equipment that operators must handle and transport. Cerakote at 0.5-2 mils saves 200-400g per part versus powder coating. ISO 9001 certified.

Cerakote coating consistency check at ColoradoKote

Weight Reduction for Aerospace Components

Thick coatings add avoidable weight to lightweighted airframe structures. Cerakote at 0.5-2 mils delivers 200-400g savings per part versus powder coating. AS9100-certified with full traceability.

Processes

How We Deliver Wear Protection

Full protection at 0.5-2 mils versus 4-6 mils for powder coating.

Spray booth preparation for Cerakote application
Spray

High-velocity application

Atomized coating reaches every surface and crevice.

Part masking detail for Cerakote at ColoradoKote
Immersion

Complete submersion coating

Total coverage for complex geometries and internal passages.

Cerakote thickness measurement at ColoradoKote
Brush

Precision hand application

Controlled placement for selective protection on assemblies.

Before and after Cerakote coating comparison
Electrostatic

Charged particle deposition

Uniform thickness with minimal overspray and material waste.

Aerospace fasteners tested in the field

A military contractor needed corrosion resistance on landing gear fasteners exposed to salt spray and thermal cycling. ColoradoKote's ceramic coating passed 5,000+ hours of ASTM B117 testing with zero red rust.

Final inspection station at ColoradoKote

Frequently Asked Questions

Find answers about our coating processes and technical capabilities

Can Cerakote provide color coding or branding on agricultural equipment?

Yes. Our over 200 standard colors and custom color matching to Delta E 1.5 accommodate OEM brand colors, safety markings, and identification coding on agricultural equipment. Cerakote's UV stability and abrasion resistance maintain color accuracy through seasons of outdoor exposure that fade conventional agricultural paint. This keeps branded equipment looking professional in the field and maintains safety color coding visibility.

How does polymer coating protect oil and gas equipment from sour gas corrosion?

Sour gas environments containing hydrogen sulfide cause sulfide stress cracking and rapid corrosion on unprotected metals. Polymer coating provides a continuous barrier that prevents H2S contact with the metal substrate. The coating flexibility accommodates the pressure and temperature cycling inherent in production operations without cracking that would expose the substrate. This protection extends equipment service life and reduces failure risk in sour gas environments.

How does the chem conversion plus Cerakote stack maximize adhesion under abrasive service?

Chemical conversion coating creates a chemically bonded interlayer between the substrate and Cerakote. Under abrasive service, this interlayer prevents the delamination that occurs when coatings are applied directly to bare metal. The result is that even when the surface layer of Cerakote wears under sustained abrasion, the remaining coating stays bonded rather than peeling away in sheets. ColoradoKote runs both processes in-house under one quality system, ensuring the interlayer is applied to a freshly prepared surface without contamination.

Is polymer coating suitable for components that experience thermal cycling?

Yes. Polymer coating's flexibility makes it particularly well-suited for components that cycle between temperature extremes. The coating expands and contracts with the substrate without cracking, delaminating, or losing adhesion. This thermal cycling durability is critical for engine components, exhaust systems, industrial process equipment, and outdoor installations that experience daily or operational temperature swings. Cerakote V-Series handles extreme heat up to 2,000 degrees F, but polymer coating handles the flex that comes with thermal cycling better.

How does ultrasonic cleaning prepare oil and gas components?

Oil and gas components accumulate wellbore fluids, scale, paraffin, corrosion products, and chemical treatment residue that must be removed before recoating or inspection. Ultrasonic cavitation breaks down these deposits in complex geometries including threaded connections, internal bores, and flow passages. Solution chemistry is selected based on the specific contamination profile. For components proceeding to coating, verified cleanliness ensures proper adhesion of the protective coating system.

Protect Your Parts From Wear

Request a wear protection quote. We respond within 24 hours with technical approach and pricing.