Electric motors drive factory automation and HVAC systems all around the world. They are also used on electric vehicles (EVs) and in ships around the world.
Long-term reliability depends on the type of coatings used on the various components. The right coating can determine how long an electric motor will operate.
Why Component Protection Matters for Electric Motors
Unexpected motor failure increases the need for emergency repairs and results in unplanned downtime costing 11% of revenue for the world’s 500 largest companies. The majority of industrial motor breakdowns start with ‘preventable’ causes within the motor.
Combatting wear on non-moving parts
Contact between bearings & shafts for thousands of hours can create wear by grinding off surface areas and increase tolerance.
Studies have identified bearing-related faults to be the leading cause of mechanical breakdowns. Once wear exceeds the threshold, the motor draws more current and runs at a higher temperature, causing additional damage.
Preventing Damage from Corrosion
Corrosion is a constant threat to electric motors located in wet or chemically aggressive areas. The most common cause of corrosion results from electrochemical reactions in which the metal’s atoms oxidize to create various compounds, including iron oxide.
When general corrosion occurs, it uniformly removes material from the exposed surface and weakens the base material, while also pushing debris into adjacent assemblies.
Insulating Against Electrical Shorts and Breakdown
Electrical insulation failures can be just as destructive as mechanical wear. Stray currents travel through motor windings and cause damage to lamination and insulation by burning them through too.
When it comes to high-voltage applications such as EV drivetrains and industrial servos, insufficient dielectric protection results in leakage of current and energy loss to the surrounding environment.
The electrical insulation of a motor is meant to ensure that electrical current does not travel along unintended paths within the structure of the motor by using dielectric coatings.
Overview of Electric Motor Coatings
The different electric motor coatings make a decision based on the type of service the motor will perform and what is required by the designed use.
Thermal Spray Coatings for Durability
Thermal spray is accomplished by firing at high speeds molecules of hot material against a surface so that, upon contact, they flatten out and fuse together during cooling. The high velocity oxy fuel or HVOF method of spraying produces a dense layer with strong adhesion, making it the best choice for wear-resistant applications of carbide or metal alloy materials.
Plasma spray is capable of melting ceramics like aluminium and chromium oxide with temperatures of greater than 15,000°, the result being an extremely durable insulating layer of electrical resistance for use on parts needing both wear protection as well as electrical insulation.
Plating for Corrosion Resistance and Conductivity
To protect against corrosion and increase hardness, metal plates deposit thin layers of metal on components. Two processes – electroplating and electroless – are used to apply plating. Electroplating uses electric energy to deposit metal ions onto the surface, while electroless plating uses a chemical reaction, without the need for additional electricity.
Because of this, electroless plating coats each part uniformly and with the same thickness, including into hard-to-reach places, whereas electroplating generally gives a smoother finish and works much faster. Plated components include connector surfaces and end shields in building motors.
Matching the Coating to the Application
A motor in a marine environment needs a coating built for corrosion resistance, best created using either electroless nickel plating or thermal spray barrier coating.
Corrosion-resistant coatings do not meet the criteria of a high-speed manufacturing line where the hardness of the surface and lowering of friction are critical (HVOF tungsten carbide).
Coatings applied via plasma spray to provide dielectric insulation and stability in electric vehicles’ electric motors are ceramic-based and fall in line with that business.
3 Top Engineered Coating Providers
The companies below earned their spots through depth in materials science and proprietary coating processes, backed by documented results for industrial and automotive customers.
1. Fisher Barton
Fisher Barton has built its reputation on extending the lifespan of high-wear components. The company’s Thermal Spray Technologies division works directly with original equipment manufacturers (OEMs) to solve friction and wear problems, drawing on decades of materials science experience. An in-house technology center validates coating performance under each customer’s actual operating conditions.
Fisher Barton’s proprietary FUSIONbond process creates metallurgically bonded coatings with less than 1% porosity and strong resistance to both wear and corrosion. The company also applies dielectric coatings to EV motors and battery components, meeting the high dielectric strength and thermal stability requirements of electric vehicle platforms.
Key Features:
- Offers proprietary coating solutions, including FUSIONbond and FluxFuse
- Extends component lifespan to increase return on investment
- Partners with OEMs across automotive, energy, medical, and industrial sectors
- Engineers’ dielectric coatings for EV motor and battery component protection
2. Linde Advanced Material Technologies
Linde Advanced Material Technologies, previously Praxair Surface Technologies, has been in thermal spray coatings for decades.
The company manufactures coating equipment, systems, materials, and powders used across aerospace, automotive, energy, and general industrial applications. Its TAFA-branded spray platforms cover plasma, HVOF, and arc spray processes.
Linde AMT’s coating materials span ceramics, carbides, metal alloys, and fluoropolymers, giving engineers the flexibility to match insulation and durability requirements for each application. Its chrome-free SERMATEL and EXOGARD systems replace traditional hard chrome plating with a lower environmental footprint.
Key Features:
- Supplies a wide catalog of coating materials, including ceramics, carbides, metal alloys, and fluoropolymers
- Produces chrome-free SERMATEL and EXOGARD systems for environmental compliance
- Operates globally with custom-engineered solutions for large-scale industrial projects
- Manufactures proprietary thermal spray equipment under the TAFA and Genie brands
3. ASB Industries
ASB Industries rebuilds and enhances industrial equipment using advanced thermal-spray technologies in Barberton, Ohio. The company offers HVOF, plasma spray, flame spray, and electric arc capabilities, with a particular focus on dimensional restoration.
For manufacturers looking to skip the cost of full replacement, ASB Industries offers a solid middle ground. Ceramic and carbide coatings restore wear surfaces and add protection for a longer service life.
The company also operates a metallography laboratory for coating analysis, enabling customers to verify that reclaimed parts still meet original performance specifications.
Key Features:
- Restores dimensions and reclaims worn motor components
- Applies tungsten carbide, chrome carbide, and ceramic coatings for wear resistance
- Operates an on-site metallography laboratory for coating analysis and quality verification
- Reduces costs by reclaiming parts instead of replacing them
Final Thoughts on Maximizing Motor Lifespan
The right coating affects performance, reliability, and total cost of ownership over a motor’s lifetime.
Every operating environment is unique and therefore has its own combination of wear, corrosion, thermal degradation, and electrical stress, thus requiring an electric motor coating designed for that environment.
A true material scientist can turn component protection from merely “cost” into lasting performance advantages.