When NASA scientists created a protective coating for ceramic materials (PCCM) for use in heat shields on space vehicles, they probably did not envision the technology used in the automotive industry. However, testing showed other possibilities for the coating, which absorbs energy to a cooler surface in turn providing greater energy efficiency and protection.

Two silicon-dioxide-based ceramic tiles were tested using an oxy-acetylene torch hot enough to cut metal. The untreated tile (left) melted and turned to glass beads within 30 seconds. Under the same conditions, the tile on the right with Wessex's PCC coating, was tested for two minutes and showed little damage.

PCCM was originally developed for use with the next generation of Space Orbiters to protect against extreme conditions upon re-entry. In 1996, Ames Research Center entered into a partial-use license agreement with Wessex Incorporated of Blacksburg, Va. for the technology. In 2001, the agreement grew into an exclusive license and expanded commercial potential. Emisshield, the name Wessex assigned to its PCCM product, is used in a variety of industries: building materials, metal and refractory coatings, automotive and military applications.

Wessex has had a great deal of success with Emisshield, most notably in industry where the product has provided energy savings, corrosion control and improved thermal heat transfer in furnace/kiln applications. When applied to various automotive parts, the coating has been proven to increase engine efficiency by utilizing fuel more effectively when applied to header pipes. In addition, testing reveals that Emisshield reduces the time a catalytic converter takes to reach operating temperature.

When applied to the exterior header and back exhaust of a V-8 big block engine, Emisshield reduced the temperature inside the racecar, improved engine performance and improved the life of the engine and header pipes. Comparison of an uncoated engine and one coated with Emisshield on an 800-cubic inch, V-8 pro-stock dragster engine resulted in an increase of horsepower, a 26-pounds-per-hour decrease in fuel usage and a decrease by almost half in outer skin temperature.

In addition, the coating has been applied to Xenon headlights, which turn a brownish-color when the internal temperature of the headlamp reaches 900 degrees Fahrenheit because the mild steel structure of the light melts. When coated, the temperature readings with Emisshield were over 200 degrees Fahrenheit cooler and the assembly steel did not melt allowing the headlamp to retain a blue-colored light.

NASA honored Wessex in June 2003 as a "Turning Goals into Reality" commercial technology award recipient. Ames continues to work with the company to identify other applications for Emisshield related to NASA's current research projects. As well, Wessex entered into partnerships with ANH Refractories of Pittsburgh and Thorpe Corporation of Houston to increase distribution of the coating and is working with various branches of the military on additional testing.

NASA Official: Jonathan Root • Web Design: Printing & Design Office, NASA Headquarters • Credits