Completed Projects of Thermal Spraying (Process Technology)


Portrait photo Heinemann © Copyright: Carl Brunn


Hendrik Heinemann

Chief Engineer and Team Leader TS-P


+49 241 80-99944



Manipulation of the electric arc inside of a cascaded (DC-SCSAPG) to improve the coating properties

Short description:

This research project focuses on the investigation of the plasma column in novel cascaded direct current single cathode single anode plasma generator (DC-SCSAPG). To observe it´s behaviour, numerical simulations of the plasma generator are conducted. With the help of the project partner, the Institute of Plasma Technology and Mathematics of the Federal Armed Forces, Munich, Germany, the position of the plasma column attachment point is located experimentally. In a further step, this position shall be manipulated with the help of external magnetic fields. Subsequently, the influence of this manipulation on the coating properties is investigated. Poster BO 1979/50-1

Förderinstitution: German Research Foundation (DFG)
Projektnummer: BO 1979/50-1
Laufzeit: November 1, 2017 to July 31, 2021

Developing a method for in-situ determination of the deposition efficiency in thermal spraying

Short description:

The aim of the research project is to develop a new method to determine the deposition efficiency as the difference between the mass flow rate of the incoming particles and the particles bouncing off the substrate. The particle sizes and velocities are determined by optical particle diagnostics. The deposition efficiency of different process parameters is derived from this data. As a result, the coating development process is accelerated. Poster BO 1979/51-1

Funding: German Research Foundation (DFG)
Porject number: BO 1979/51-1
Duration: April 1, 2018 to June 30, 2021

Thermally sprayed heating coatings for the application in plastics processing

Short description:

In this research project, a thermally sprayed coating system for the heating of injection moulding tools is developed in cooperation with the project partner obz innovation GmbH. The aim is to achieve shorter cycles and less defects in injection moulding. One of the challenges is the required power input into the coatings to achieve the desired heating rates. Likewise, the project focuses on proving the resistance of the coating system against the loads in injection moulding. At the end of the project, a demonstrator will be built to prove the applicability of the developed coating system.Poster ZF4059003SU6

Funding: Zentrales Innovationsprogramm Mittelstand (ZIM)
Porject number: ZF4059003SU6
Duration: April 1, 2017 to March 31, 2019

Determination of the formation mechanisms of emissions during thermal spraying with a focus on ultrafine particles and the risk assessment of individual dusts under production-relevant conditions

Short description:

The potential risk of airborne particles has been known for a long time, but cannot be assessed with sufficient accuracy, especially in thermal spraying (TS). Especially due to insufficient research results regarding the formation mechanisms, coating development and process design. Therefore it is of overriding interest to close existing gaps in knowledge and to further clarify possible risks on the basis of reliable data. A major goal is to reduce dust generation, especially the ultrafine fraction, during the spraying process. The first task is to clarify the mechanisms on which the formation of emissions, especially the ultrafine particles, is based and to what extent this formation can be influenced by variations in material compositions, thermal spraying processes and process parameters. In addition, the resulting emissions are assessed with regard to their toxicity. Emissions from thermal spraying represent an important research focus for the surface technology industry, which is being investigated in cooperation with the Institute for Occupational, Social and Environmental Medicine (IASU). Poster 18.653N

Funding: Joint industrial research and development (IGF)
Porject number:


Duration: August 1, 2016 to March 31, 2019

Development of a method for the qualification of sealers for thermal spray coatings

Short description:

The aim of the research project is the development a new method to qualify novel sealers for thermal spray coatings. Thermal spray coatings can exhibit a certain degree of porosity, e.g. to reduce their thermal conductivity. Sealers can be used to close these pores. Established methods for the qualification of these sealers are, however, complex and expensive. Therefore, a new method, based on the gas flux through the sealed coating, is developed. Based on the results, small companies can develop and qualify new sealers faster and more cost-efficient. Poster Zf4059001CK5

Funding: Central Innovation Programme for SMEs
Porject number: Zf4059001CK5
Duration: November 1, 2015 to October 31, 2017


Sustainable corrosion protection of offshore wind turbines by sealed thermal spray zinc coatings

Short description:

The aim of this research project is the development of zinc-based, thermally sprayed corrosion protection coating for offshore wind turbines. Through the holistic approach – from material development to post treatment – the understanding of coating build-up as well as the corrosion mechanisms could be deepened. This resulted in a significant lifetime increase while the costs for the coating application were reduced. Poster 0325672C

Funding: Bundesministerium für Wirtschaft und Energie (BMWi)
Porject number: 0325672C
Duration: 01.11.2013 bis 30.04.2017