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

Theleis – Thermally sprayed coatings with good thermal conductivity and electrical insulation

Short description:

In this research project, a thermally sprayed coating is developed which has good thermal conductivity and at the same time ensures the electrical insulation of electrical components. This is implemented in cooperation with the project partner obz innovation GmbH. Increasing the power densities, especially in fast charging in e-mobility, lead to rising operating temperatures of the power electronics. Therefore, an adequate heat dissipation for electrical components while maintaining the electrical insulation is necessary. By varying the material chemistry and the microstructure of the applied coatings, the thermal resistance of the insulation coating is to be reduced without limiting the insulating effect. The functionality of the developed Theleis coating can be verified with the aid of application-oriented tests.

Funding: Central Innovation Programme for SMEs
Porject number: KK5370601SU1
Duration: January 1, 2022 to December 31, 2023

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 28, 2023

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 January 31, 2023

HEA-Heiz – 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. Poster HEA-Heiz

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