Completed Projects of Thermal Spraying (Shield Coatings)


Portrait photo Olesch © Copyright: Carl Brunn


Elisa Olesch

Team Leader TS-S


+49 241 80-99963



WEAREND2 - High-end wear-resistant WC-Co materials

Short description:

This project is aiming to investigate and upscale the utilization and production of a novel Nano-WC/Co hard metal powder for Thermal Spraying. The VTT in Finland is producing laboratory scale batches of the spray powder from water-soluble components using a novel powder manufacturing route. The spray powder is then characterised and Thermal Spraying tests with different parameter sets are conducted at the IOT. The properties of the coating are thereafter analysed and compared to commercial references.

Funding: EIT Raw Materials
Project nuber: 19026
Duration: 01.01.2020 to 31.12.2022


EBC4CMC - Development of novel creep resistant bond coats for “Environmental Barrier Coatings”

Short description:

Ceramic Matrix Composites (CMCs) are used in modern aeroplane engines to realize higher temperatures and thus an increase in efficiency. In particular, the promising components made of SiC composites are protected against water vapor-induced corrosion at high temperatures with an "Environmental Barrier Coating" (EBC). The service life of the EBC coating system depends, among other things, on the properties of the Si bond coat in the EBC. The aim of this research project is to develop new Si-based bond coats with improved properties by Si3N4 or SiC reinforcement. For this purpose, new spray feedstock materials are designed and developed. The coatings are developed by plasma spraying and HVOF spraying. The coatings are characterized and investigated with respect to coating structure, phase composition, mechanical as well as thermo-physical properties. With the help of isothermal aging, the oxidation behavior of the coatings at high temperatures is investigated. In addition, the possibility of further improving the coating properties with the aid of heat treatment will be explored.

Funding: German Research Foundation (DFG)
Porject number:


Duration: December 1, 2020 to November 30, 2022


Development of a design method for an innovative bearing concept

Short description:

The focus of the research project is on the further development of the thermally sprayed coating system based on a cobalt-based alloy with hexagonal boron nitride. This coating system supports the use of a new type of sliding bearing geometry for the main drive train in wind turbines. Initial demonstrator investigations have already confirmed the potential under operating conditions. The hexagonal boron nitride serves as solid lubricant embedded in the wear-resistant cobalt base matrix. Within the scope of the project, the particle state variables during the coating process are influenced by parameter variation, thus changing the distribution of the solid lubricant within the matrix. The influence of the process parameters on the tribological properties of the TS-coatings will be investigated by high load tests in a ring-disc tribometer in order to achieve a further reduction of friction and wear.

Funding: Federal Ministry of Economics and Energy
Porject number:


Duration: November 1, 2019 to October 31, 2022

WEGA - Material development for sliding stressed applications

Short description:

The research project focuses on the development and investigation of novel coatings for sliding applications. Coatings made of a metallic base with embedded solid lubricants, which cannot be produced by smelting metallurgy, are developed by means of thermal spraying. In order to increase the performance of sliding coatings, higher metal contents compared to conventional sintered metals and finer distributed solid lubricants compared to bronze bearings with graphite inserts are promising material combinations. The aim of the research project is to adjust the metal content and the distribution of the solid lubricants with regard to the application in order to minimize friction and wear.

Funding: German Federation of Industrial Research Associations (AIF)
Project nubmer: 20571 N
Duration: March 1, 2019 to February 28, 2022

Electrical Insulating Surface Coatings based on High-Performance Composite Materials for Bearings in Drive Trains

Short description:

The aim of the project is to increase the lifetime of drive trains in rail vehicles, which break at an early stage due to parasitic currents running through the bearings. Therefore, novel electrically insulating composite materials are under development. These will then be applied as coatings. The relevant failure mechanisms can be analysed by combining different matrix- and filling materials like Al2O3, PEEK and spinel and further improve the microstructure of the coatings. Moreover, the electrical properties of each coating system are adjusted with respect to the requirements of the application. The measurements of the electrical material properties consider frequencies between 10 mHz und 1 MHz. Applicable coating systems are also tested tribologically and mechanically to be qualified as coatings for bearings. Poster 03XP0167C

Funding: Bundesministerium für Bildung und Forschung (BMBF)
Porject number: 03XP0167C
Duration: September 1, 2018 to August 31, 2021

KOKON II - Reliable corrosion protection for highly stressed flange connections in offshore wind turbines

Short description:

The aim of the research project is the development of novel corrosion protection coatings for slip free flange connections in OWT. During service, these coatings are exposed to marine atmosphere; a reliable corrosion protection is, however, required to prevent slip over the entire lifetime of the OWT. First, the mechanical properties and the corrosion behaviour of established coating systems is analysed. Based on the results, novel feedstock materials are developed and deposited using an adapted coating process variant. Poster 0325672E

Funding: German Research Foundation (DFG)
Porject number: BO 1979/51-1
Duration: April 1, 2018 to March 31, 2020

HV-Roller - Development of innovative, iron-based wear and corrosions resistant coatings for the paper manufacturing industry

Short description:

The aim of the research project is the design of an innovative and economic feedstock material and the qualification of the corresponding coatings under consideration of the load collective in paper manufacturing industry. Due to the complex load collective the rollers need to be protected from corrosion and wear over the entire surface. Among other this will be complied with an amorphous microstructure in the coating and the addition of hard phases. Poster KF2441310SU4

Funding: AiF-ZIM
Porject number:


Duration: 01.07.2018 to 30.06.2020

Fe-TiC II - Further development of thermal sprayed TiC-reinforced Fe base coatings for wear protection under corrosive conditions

Short description:

The aim of the research project is the further development of thermal spraying iron-based coating systems reinforced with TiC. In previous projects, these TiC/Fe systems were able to demonstrate high potential in hydraulic applications. Due to the Cr and Ni rich Fe matrix, good corrosion resistance can be achieved. The TiC content of 34 wt.% leads to excellent wear protection of these coatings. Due to the modifications of the spray powder and process parameters, the TiC/Fe coatings can meet the high requirements of the hydraulic industry, especially in aggressive corrosive environments. The properties of the coatings will be tested in a practical hydraulic test bench. Poster IGF 19.451 N

Funding: Cooperative Industrial Research (IGF)
Porject number:

IGF 19.451 N

Duration: April 1, 2017 to September 30, 2019

WTG - Thermally sprayed sliding bearings for main bearing of wind turbine generators

Short description:

The aim of the joint project is the fundamental development and validation of a material concept, based on novel thermally sprayed coatings, for the realization of sliding bearings for main bearing of wind turbine generators (WTG). The material concept includes the determination of the material components, the coating morphology and topography as well as the load-specific geometry and the manufacturing process of the bearing coatings. Promising coating systems will be developed, characterized and evaluated. Thermal spraying in particular offers the possibility of realizing material concepts that cannot be produced by melting metallurgy so that the increased requirements of this highly stressed bearing location can be met in the future. The production of these innovative sliding bearing coatings for WTG main bearings by thermal spraying (TS) represents a novel research approach which is being investigated in cooperation with the Chair for Wind Power Drives (CWD). Poster 03EK3036A

Funding: Federal Ministry of Education and Research (BMBF)
Porject number:


Duration: December 1, 2016 to December 31, 2018

PTWA-Engine - Development of a process for coating deposition on inner surfaces of combustion engines with a corrosion resistance and friction reducing iron-based material

Short description:

The aim of the research project is the development of an innovative feedstock material for the deposition on inner geometries of combustion engines. Due to the special torch design and the individual alloy the feedstock material needs to be designed as a cored wire. In order to improve the process stability and implement an economic processes, the design of torch is improved by a project partner. Finally, the innovative coating materials are evaluated with regard to the post machining by means of honing by a project partner. Poster KF2441310SU4

Funding: AiF-ZIM
Porject number:


Duration: 01.04.2015 to 31.09.2017