Metals: Almost every structural metal can be coated successfully with Xylan, including steel (carbon and stainless), aluminum (wrought and cast), copper (and alloys), and titanium. Note: High nickel- and chrome-bearing alloys, and some platings of nickel, can also be coated if abrasive blasting is used and the coatings are applied within an hour or two of preparation.

Special precautions must be taken when coating powder metal (PM) parts. At first glance, PM parts would appear to be ideal candidates for coating: their surface is porous and provides good "tooth" to which a coating can cling. However, since many of these parts have been treated with resinous impregnants, oils are trapped within the porosity of the parts. To coat them successfully, bake the parts at a temperature that is higher than the anticipated cure temperature of the coating. Any contaminants which bleed to the surface during the bake must be thoroughly removed. Then, the PM parts are ready for coating.

Die-cast parts are another special case. These components are typically cast using aluminum, zinc and magnesium alloys that can be "gassy" and porous.

When coated parts are placed in an oven and heated, the gas trapped in internal cavities expands and erupts. When cured at over 205°C/400°F, these parts may have numerous eruptions on the coated surface. To avoid this, cure the parts under 205°C/400°F.

Plastics: Many plastic materials can be coated successfully with Xylan, including nylon, PEEK, PEK, PPS, ABS, polycarbonate, epoxy, polyester and phenolic. The exceptions are the polyolefins and fluoropolymers — both of which have natural release characteristics. Also, vinyl products containing a high content of plasticizer can cause adhesion problems.

Parts made of these materials must be cured at temperatures well below the softening temperature of the substrate to avoid distortion and polymer degradation.

Elastomers: Some Xylan coatings may be applied successfully to elastomeric parts not expected to elongate more than about 30 percent in service. Elongation greater than this may cause the coating to crack. Note: If a discontinuous coating is not objectionable, elongation far greater than 30 percent is permissible.

Elastomeric parts successfully coated with Xylan include bushings, mounts, automotive door and window seals, vibration dampers. Suitable substrates include natural rubber, EPDM, SBR, butadiene and its derivatives.

Glass and ceramics: Fluoropolymer coatings will adhere to clean ceramic or glass surfaces, but curing the coating without cracking the substrate can be difficult. (If possible, use glass or ceramic intended for high temperatures.) In most cases, a low-temperature cure (below 150°C/300°F), followed by a slow cool-down period, will not crack the substrate. For glass parts, coating adhesion may be improved by a fluorine etch.

Fabrics and composites: Xylan coatings are being increasingly used on woven and non-woven industrial textiles made from such modern materials as carbon fibre for low friction and release at elevated temperatures. One of the most successful applications of Xylan involves a fabric bearing which is woven from a nylon/glass blend, then coated and cured.

These composite bearings are used under the compressor blades of large fanjet engines. The natural porosity of fabrics forms sponge-like "wells" into which the coating can penetrate. In service, this extra supply can continue to provide PTFE to a wear surface long after the coating has worn away from a smooth substrate.

Xylan adheres well to other composites too, provided release agents have not been applied to the material.

Paper and wood: Xylan adheres well to uncoated or unvarnished paper products as well as wood. As unlikely as it may seem, the coatings perform every bit as well as they do on metal and other substrates. Cure temperature should not exceed 180°C/350°F.