Thermal Spraying (Process Technology)


Portrait photo Heinemann © Copyright: Carl Brunn


Hendrik Heinemann

Chief Engineer and Team Leader TS-P


+49 241 80-99944



CoE-IoP – Cluster of Excellence "Internet of Production" - Subproject WS-B2.II “Discontinuous Production”

Short description:

Within the subproject WS-B2.II “Discontinuous Production”, different aspects of Industry 4.0 are investigated. Artificial intelligence methods are used to predict particle properties based on process parameters. The creation of a digital shadow of the TS and PVD coating processes will be implemented by a digital networking of the coating equipment in combination with process simulations. Furthermore, a digitized connection of the analysis equipment and automated transfer to a database will be implemented. The collected data will be used to predict coating properties and for specific control and parameter selection for the coating process. Poster CoE IoP Subproject WS-B2.II

Funding: German Research Foundation (DFG)
Porject number: EXC 2023/1
Duration: January 1, 2019 to December 31, 2025

HVAF-Sim – Simulation-based process development for the application of MCrAlY coatings using the AC-HVAF process

Short description:

The aim of the project is to develop AC-HVAF (Activated Combustion High Velocity Air Fuel) processes using numerical simulation for the application of MCrAlY coatings. For this purpose, it is necessary to study the flow and combustion phenomena during the process, since they can influence the in-flight behaviour of the particles. The particle velocity in the free-jet stream will be determined using process diagnostics to validate the simulation model. The properties of the coatings will be analysed to derive the correlation between the process parameters and the coating properties. Poster HVAF-Sim

Funding: German Research Foundation (DFG)
Porject number: 437084607
Duration: March 1, 2021 to February 29, 2024

PlasmaNozzle – Increasing the energy efficiency of plasma spraying by means of simulation-based process development

Short description:

The primary goal of the project is to investigate the potential for increasing the energy efficiency of plasma spraying by using a fixed nozzle extension. The nozzle extension should surround the plasma free-jet and thus prevent air entrainments from mixing with the plasma gas. In order to investigate the influence of such nozzle extension and to optimize its geometry, the existing simulation models of the plasma jet should first be extended accordingly. The geometry of the nozzle extension should then be optimized using algorithms (genetic algorithms or particle swarm optimization) and experimentally validated. Besides energy efficiency, the nozzle extension also offers great potential to improve the coating properties. Thus, the possible influence of a fixed nozzle extension on the coating properties, such as the porosity or oxide component, will be investigated in this project. Poster PlasmaNozzle

Funding: German Research Foundation (DFG)
Porject number: BO 1979/79-1
Duration: February 1, 2021 to April 30, 2024

ProKI-Netz - Demonstration and Transfer Network AI in Production

Short description:

The coating technology industry is often characterized by small and medium-sized enterprises (SMEs) where AI applications are relatively rare. The project ProKI-Netz aims to harness the existing potential and support companies in the industry with the successful implementation of AI.

To achieve this goal, various approaches are employed. These include providing free consultation sessions to address the specific needs of SMEs regarding the implementation of AI in areas such as Thermal Spraying. Support for AI implementation is offered through transfer measures, lectures, and workshops. Additionally, the developed AI demonstrators are directly evaluated in interested companies to ensure their alignment with industry requirements. Poster ProKI-Netz

Funding: Federal Ministry of Education and Research (BMBF)
Project number: FKZ 02P22A000 to 02P22A070
Duration: November 1, 2022 to October 31, 2024


Development of simulative approaches for specific development of the properties of plasma sprayed coatings

Short description:

Project A10 deals with the tailored development of plasma-sprayed heat insulation coatings by means of numerical prediction. During atmospheric plasma spraying, not only process parameters but also disturbances influence the process characteristics. As a result, processes that occur during the transition of the coating building particles from the solid into the (partly) liquid state and from the (partly) liquid state into the solid state are also influenced. The correlation between the process parameters and the coating properties were successful in the first phase of the project, both numerically and experimentally. The focus of the second phase of the project lies on the analysis of disturbance-dependent process changes by means of modeling and simulation. The aim of the second phase is predicting the coating properties while taking into account the disturbances that occur in the real processes. Poster SFB 1120 – Subproject A10

Funding: German Research Foundation (DFG)
Project number: SFB 1120 – Teilprojekt A10
Duration: July 1, 2022 to June 30, 2026

Experimental analysis of thermo-mechanical properties of thermally sprayed coatings

Short description:

Increasing the precision of the parts produced in the melt related production processes is the central research focus of the Collaborative Research Center 1120. In general, the precision can be significantly increased by specifically controlling the heat inflow and outflow. With the help of thermally sprayed coating (TS coatings), the heat transfer on the surface can be specifically controlled by increasing or decreasing the thermal conductivity of the passive TS coatings or by locally generating heat on the surface with the help of the electrical heater coatings. In this project thermally sprayed electrical heater coatings will be considered as the heat source. In contrary to the thermal insulation coatings, the porosity is no longer the dominant factor, rather the electron and phonon conduction in solids should be taken into account. Poster SFB 1120 – Teilprojekt A12

Funding: German Research Foundation (DFG)
Project number: SFB 1120 – Teilprojekt A12
Duration: July 1, 2022 to June 30, 2026