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Chair of Materials and Surface Engineering
Thermal coating

Thermal Coating Department

Bild Uebersicht Abteilung Thermisches Beschichten

Welcome to the Thermal Coating Department.

The functionalisation of surfaces using thermal coating processes is the focus of our department. We can draw on many years of experience in the field of thermal spraying and have all the important spraying processes in our portfolio, from powder and wire flame spraying, arc spraying and high velocity flame spraying (HVOF, HVCW) to atmospheric plasma spraying (APS) and cold gas spraying (CGS). In addition, we will soon have a state-of-the-art laser cladding facility at our disposal and thus expand our spectrum to include surface-remelting coating processes.

On the materials side, our research includes the application of metallic, ceramic and composite powders to a wide variety of substrate materials (metals, ceramics, polymers, glasses, organic natural materials such as woods, composites, etc.). High-energy ball milling is a flexible process that allows us to produce our own powders and optimise them in terms of alloying technology. Other important fields of work range from substrate pre-treatment (blasting technology) to process diagnostics and simulation to various post-treatment and characterisation methods for the coatings produced. Our department also has extensive know-how in the development of thermal spray torches and –nozzles.

Under the tabs displayed at the top edge of this screen area, you will find more detailed information on our research achievements, the services we offer and the extensive equipment and methodological facilities of our department.

Do you have any further questions or can we support you in your tasks? Then simply contact us at the telephone number or e-mail address below.

We look forward to working with you!

The current research foci of the Thermal Coating department are broad. They include the characterisation of changes in the coating material composition (in particular hard material components) during the thermal spraying process, the design of component structures coated by means of thermal spraying in accordance with residual stress, the investigation of adhesion mechanisms between cold gas sprayed metallic layers and ceramic substrates as well as the optimisation of thermal barrier coatings (TBCs) e.g. for turbine blades.

Furthermore, our team deals with the thermochemical post-treatment of thermally sprayed iron-based coatings, with the spray processing of high entropy alloys as well as with the influence of the substrate surface geometry on the coating properties.

In the future, the combination of laser-based methods with thermal spraying will play an important role in our research work, which should set new impulses in the field of generative manufacturing.

Below you will find a selection of our most important research topics.

We will be happy to advise or support you with our expertise in solving your tasks.
Just get in touch with us!

The range of services offered by the Thermal Coating department includes not only the application of thermally sprayed coatings but also their mechanical and microstructural characterisation. Likewise, the diagnostics and simulation of thermal spray processes as well as the production of mechanically alloyed powders by means of high-energy ball milling are part of our portfolio.

The technical equipment available to us for this purpose can be found sorted by laboratory area under the corresponding tab on this page.

We offer the following services as standard.

Contact us if you would like us to support you in special tasks!

  • Application of thermally sprayed coatings with the following processes:
    • Powder Flame Spraying (PFS)
    • Wire flame spraying
    • Arc spraying (AS)
    • High velocity powder flame spraying (HVOF)
    • High velocity wire flame spraying (HVCW)
    • Atmospheric Plasma Spraying (APS)
    • Cold Gas Spraying (CGS)
  • X-ray fine structure analysis using XRD:
    • qualitative and quantitative phase analysis and determination of the lattice parameters
    • Determination of particle sizes and micro distortions
    • Residual stress measurement
    • Texture analysis
    • Coating thickness, roughness and density determination by means of reflectometry
  • Simultaneous performance of thermogravimetry (TG) and optionally differential thermal analysis (DTA) or dynamic differential calorimetry (DSC)
  • Thermomechanical analysis (TMA) to determine the behaviour of materials under mechanical and thermal loading
  • Mechanical testing of coatings (face tensile test/adhesive tensile test, tensile test, bending test)
  • Fatigue testing of coated materials in the LCF range with servo-hydraulic testing machine (cyclic tensile testing in the tensile threshold range and cyclic bending testing with all load conditions).
  • Various standardised wear tests in solid contact (Taber Abraser, Rubber Wheel, Miller test, vibration friction wear test (Ball-on-Disk, Pin-on-Disk etc.)).
  • FEM and CFD simulations
  • Spray process diagnostics using a 3-channel acousto-optical emission spectrometer, Oseir SprayWatch and Oseir HighWatch
Mechanical alloying (powder phase) Melting metallurgical processes
  • Powder atomisation system
  • AMC casting device
  • Electric arc furnace (use via Professorship PVW)
Sintering process
  • Spark plasma sintering system (SPS) (use via Professorship PVW)
Heat treatment furnaces
  • Various muffle and protective gas furnaces as well as quenching baths
Additive manufacturing of polymer/polymer composite components using the FDM process
Simulation software
  • MatLab
  • Mathcad
  • Deform
  • Fluent
  • JMatPro
  • MemBrain


Thomas Lindner
Thomas Lindner
Phone: +49 (0)371 531 – 38287
Room: 3/E105