Precision Flame Treatment Enhances Ceramic Core Manufacturing at PCC Airfoils
PCC Airfoils, a global leader in advanced investment cast airfoils for industrial and aerospace turbine engines, has increased productivity and consistency of their ceramic core surface treatment process by integrating Enercon’s Flame Series plasma treaters.
The Challenge: Improving Surface Treatment Results
The ceramic core material used in the investment cast airfoils have inherently low surface energy making it challenging to achieve proper coating adhesion during the company’s injection process operations. The company had found some success with an air/gas burner mounted on a robot. While it was functional, it lacked the precision PCC required.
“We were using a torch head on a robot arm,” explains Andrew Bloom, LP Senior Product Engineer at PCC Airfoils. “It did the job, but it was hard to get an accurate treatment pattern and difficult to maintain consistent treatment intensity.”
The Solution: Enercon Flame Series Plasma Treaters
PCC connected with Enercon through their automation vendor, I-C Automation. To help in their evaluation of Enercon’s Flame Series 400 plasma treater, Enercon provided a consignment unit for proof-of-concept testing. This allowed PCC to validate Enercon’s high velocity drilled port burner design and combustion control technology in real-world conditions.
“We used the consignment unit to prove out the process,” says Bloom. “It gave us the chance to test the drilled port burner and see how it performed in our environment. The results were impressive.”
Enercon’s flame treaters are designed to clean, etch and functionalize the ceramic surface to promote better bonding. The drilled port design produces a powerful high velocity flame ideal for ensuring consistency while operating at high speeds.
The Enercon flame treaters quickly won over the PCC Airfoils team. Treatment consistency improved, the system offered superior intensity control, and treatment times were significantly reduced – all of which are key factors in preparing ceramic surfaces for coating and adhesion applications.
Additionally, the Enercon flame treaters also provided built-in fail-safe features to ensure safe operation and proper ventilation over the torch head PCC was previously using.
Growing Adoption and Expansion
Following successful trials, PCC began integrating Enercon systems into its production lines, purchasing their first flame system in 2023. Since then, they’ve added four more Enercon Flame Series Pro treaters to support their Ceramics Group operations in Wickliffe, OH.
“We’re in the process of funding an additional three units for 2026,” Bloom confirms. “Our business is doing well, and with production expansions underway, we’ll need more systems to keep up.”
Why Enercon?
PCC cites several key benefits of Enercon’s flame treaters:
- Programmable treatment intensity for precise surface treatment
- Superior build quality and reliability
- Excellent sales, customer service, and technical support
- Enhanced safety features and ability to automate
“The treatment intensity and programmability are what really stand out,” Bloom notes. “Enercon’s equipment is solid, and their support team has been accommodating throughout the process.”
Mission Critical Performance Requirements
PCC’s Ceramics operations supply ceramic cores and custom blended ceramic particulate systems used in the manufacture of investment cast blades and vanes. These components are essential to the performance and durability of turbine engines, making surface treatment a critical step in the manufacturing process.
PCC Airfoils’ adoption of Enercon flame treaters reflects a broader commitment to technological advancement and operational excellence. As the aerospace market continues to grow, PCC is well-positioned to meet increasing demand with scalable, safe, and high-performance surface treatment solutions.
“PCC Airfoils is a world leader in advanced investment cast airfoils,” Bloom concludes. “And we’re always looking for ways to improve our processes and stay ahead.”
