Madison Plasma Dynamo Experiment


The University Of Wisconsin’s Plasma Physics Department contracted Metallic Bonds to engineer and apply an alumina ceramic coating onto two halves of an aluminum cast sphere. The total area coated was 100 square feet. Each half of the sphere is 10 feet in diameter and weighs nearly 6,000 pounds. When assembled, the spheres form a chamber vessel known to the University as the “Madison Plasma Dynamo Experiment”. This chamber vessel is filled with gases forming highly conductive plasma. Temperatures in the vessel reach 500,000° F and simulate the sun’s magnetic field for experimental purposes.

The University of Wisconsin decided to use Metallic Bonds alumina ceramic coating system for this application. The main objective was insulation from electrical current. The coating allows the vessel to perform to engineered specifications and high operating parameters. In addition, the Metallic Bonds ceramic coating also provides exceptional vacuum compatibility as well as extremely high dielectric strength. In fact, the Metallic Bonds ceramic coating can resist voltages of 300 to 400 per .001” thickness. Metallic Bonds applied a coating thickness of .010” (resisting volts of 3,000 to 4,000).

Metallic Bonds can engineer and apply a coating system designed specifically to meet your needs whether it is for wear resistance, restoring a part back to size, electrical insulating, or protecting a part from high temperatures.

Capabilities Applied/Processes

Thermal Barrier Protective Coating

Overall Area

100 square feet – Two Halves of a Sphere, 10 ft. Diameter
Weight: Nearly 6,000 lbs.

Operating Temperatures

500,000°F – Additionally Simulates the Sun’s Magnetic Field

Coating Applied

Alumina Ceramic Coating

Coating Thickness


Material Substrate

Aluminum Casting

Main Objectives

Insulate from Electrical Current
Provides Exceptional vacuum Compatibility
Extremely High Dielectric Strength


3,000 – 4,000 Volts

Industry for Use


Delivery Location


Standards Met

Customer Specifications


Metallic Bonds, Ltd.

For more than 30 years, Metallic Bonds, Ltd. has been a leader in quality Thermal Spray Coating Services, Brush Plating, and Machine Component Repair.

Toll Free: 1-800-236-3307
Phone: 608-365-9299

1929 Royce Ave
Beloit, Wisconsin 53511
United States


"*" indicates required fields

This field is for validation purposes and should be left unchanged.

Powered by: Astute Web Group