Thermal insulation and shielding for high-stress exhaust systems
High-quality insulation solutions for thermally demanding applications
PTS develops and manufactures thermal insulation and self-supporting shielding for high-stress components in the automotive, motorsport and industrial sectors. Components insulated include exhaust pipes, catalytic converters, silencers, manifolds and exhaust gas turbochargers.
The systems used provide targeted protection for adjacent components against extreme temperatures, as well as the controlled guidance and channelling of thermal energy within complex assemblies.
Through a combination of technical expertise, high vertical integration and flexible manufacturing, both prototypes and series production solutions can be efficiently implemented.
Integral insulation and self-supporting shields
Our thermal insulation systems are precisely tailored to the specific application and meet the highest requirements in terms of temperature resistance, vibration resistance and integration into the installation space.
The following are used:
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The design is tailored individually to temperature loads, installation space, weight and mechanical stress.
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Materials and foils used
High-quality stainless steel foils in various grades are used for thermal shields. The selection is based on temperature resistance, formability and the specific requirements of the application.
Material grades used:
- 1.4301 – AISI 304 / X5CrNi18-10
- 1.4828 – AISI 309 / X15CrNiSi20-12
- 1.4541 – AISI 321 / X6CrNiTi18-10
Typical sheet thicknesses:
- 0.1 mm
- 0.15 mm
- optionally 0.2 mm and 0.3 mm
Particularly for prototypes and test assemblies, the thin sheet thicknesses enable flexible and precise manual fabrication of complex geometries.
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Insulation materials and temperature resistance
Different insulation materials are used depending on the operating temperature and requirements.
Typical insulation thicknesses range from 3 mm to 25 mm.
As the material thickness increases, the cost rises significantly more than the additional thermal benefit.
Fibre materials used:
- Glass fibres up to approx. 500 °C
- Silicate fibres up to approx. 700 °C
- Modified silicate fibres up to approx. 1000 °C
The fibres used are specifically designed for dynamic loads and high vibration stress in on-highway applications and differ significantly from static insulation materials used in the building sector.
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Micro-spot welding of insulation systems
Micro-spot welding enables the precise joining of thin-walled insulating films with minimal heat input. This allows multi-layer shielding and thermal insulation systems to be securely fixed without significantly affecting the material structure or dimensional stability.
The process is particularly suitable for delicate stainless steel foils and complex geometries with high demands on precision, vibration resistance and installation space.
Advantages of micro spot welding:
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Microporous insulation materials
Microporous insulation materials offer particularly high thermal insulation performance whilst taking up minimal space and being lightweight. Thanks to their extremely low thermal conductivity, they are ideally suited to high-temperature applications such as exhaust systems, turbochargers or piping systems subject to thermal stress.
They enable an efficient reduction in heat radiation and contribute to the protection of adjacent components as well as to optimised thermal management. Particularly when combined with metallic shielding and multi-layer insulation systems, they create high-performance and vibration-resistant heat protection solutions.