Thermal Spraying (Process Technology)


Hendrik Heinemann © Copyright: IOT


Hendrik Heinemann

Chief Engineer


+49 241 80 99944



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


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

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, 2018 to June 30, 2022

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, 2018 to June 30, 2022

Development of Novel Metallic Additional Materials for Heating Elements by Thermal Spraying

Short description:

This research project focuses on the investigation of high entropy alloys (HEA) for the application as thermally sprayed heating elements. HEA is a new innovative material class, which gained significant research interest in the last 15 years. By alloying elements with significantly smaller or significantly larger atomic radii the crystal lattice of the reference alloy is distorted to adjust the material properties that way. The metallurgic material development is conducted on alloys, remolten in a vacuum oven, as well as on metallic foils, which are manufactured by melt spinning. The high cooling rates of the alloy during melt spinning are used to emulate the solidification process during thermal spray.

Funding: German Research Foundation (DFG)
Project nubmer: BO 1979/76-1
Duration: October 1, 2020 to September 30, 2022

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.

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