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Machines and systems Surface coating

Functional coatings for wear, scuffing and corrosion protection as well as friction reduction

The history of surface coating in mechanical and plant engineering goes back centuries. Even in the past, intensive searches were made for solutions to increase the wear resistance of machines and systems, extend their service life and prevent surface fatigue. With our extensive product portfolio, we offer customised solutions for all surface requirements in mechanical and plant engineering. Various processes such as chemical, galvanic, PVD/PACVD or hybrid processes are used. Nowadays, different surface processes are often required in order to achieve maximum results. We are ready to develop the perfect surface treatment for your machines and systems.

Case Story

Insight into our customised solution for our customers in the field of machinery and systems.

Challenge: Wear and dry lubrication in gas compressors

Gas compressors are essential for numerous industrial applications applications, from petrochemicals to food production. The efficiency and longevity of these machines depend heavily on the performance and condition condition of their components. One of the biggest challenges with gas gas compressors is the wear caused by the high frictional forces between moving parts. moving parts. Especially under dry lubrication conditions, where no or only minimal lubricants can be used, the components are components are exposed to extreme mechanical loads. This not only leads to to increased wear and frequent failure of components, but also to a significant a significant increase in operating costs due to maintenance and replacement spare parts costs.


Solution: Coating with electroless nickel

One promising solution for reducing friction and wear in gas wear in gas compressors is to coat the parts with electroless nickel (EN). nickel (EN, electroless nickel). This coating is applied to the surface of the components applied to the surface of the components by a chemical reduction process, whereby a This achieves a uniform coating thickness across complex geometries. Electroless nickel offers excellent tribological properties, including high hardness and a very smooth surface structure, which reduces friction. In addition, the nickel layer protects the base base materials from corrosion and chemical attack, which is particularly beneficial in aggressive gas environments. gas environments.

Technical and economic benefits

The use of electroless nickel coatings in gas compressors has several technical and economic advantages. From a technical point of view, the reduced friction leads to a longer service life of the components, as wear is significantly reduced. This means less downtime and lower maintenance costs, as the intervals between maintenance cycles can be extended. In addition, the corrosion resistance of the coating improves the reliability of the gas compressors in various environments, allowing the machines to be used in a wider range of applications.

In economic terms, this results in a significant reduction in costs. The longer maintenance intervals and reduced need for spare parts lead to lower operating costs. In addition, the increased efficiency of the compressors can lead to energy savings, as less energy is required to achieve the same performance. This is particularly important in industries with high energy consumption, where any savings directly reduce operating costs and therefore improve the overall cost-effectiveness of the system.

Overall, electroless nickel plating is an effective solution for improving the performance and reliability of gas compressors by minimising friction and wear while reducing operating costs.

Case Story

Our products

An overview of our product solutions in the area of machines and systems.

Possible process variants: Electroless nickel high-phos, electroless nickel mid-phos and electroless nickel thermal post-treatment.
CERODEM WCH is a diamond-like carbon with fine metal carbide inclusions. This enables the simple reduction of friction, surface fatigue and tribo-oxidation in a proven manner.
Hard chrome plating is an electrolytic process for applying a hard chrome layer to ferrous materials, aluminium, stainless steel, copper or brass. In contrast to decorative bright chrome plating, the layers are thicker and are applied directly to the material without intermediate layers. They are primarily used to improve the functionality of mechanically stressed surfaces.
Coating with a unique combination of resistance to corrosion and mechanical wear
Electroless nickel-PTFE coatings combine the hardness and corrosion protection of nickel with the friction-reducing properties of embedded PTFE particles. They are suitable for applications with lubrication requirements, offer wear protection and prevent adhesion.
High-performance alternative to hard chrome plating. It has high oxidation resistance with good ductility.
Amorphous diamond-like carbon coating - exhibits high hardness and low dry friction losses.
Combines anti-friction and non-stick properties as well as wear and corrosion protection, which significantly improves the performance of workpieces
Excellent values for friction reduction Combines properties that significantly improve the performance of plastic injection moulding tools.
Combines anti-friction and non-stick properties as well as wear and corrosion protection, which significantly improves the performance of workpieces
Increases the service life of stressed components components thanks to maximum wear protection
Increases the service life of stressed components through maximum wear and corrosion protection
The matt nickel coating is a surface treatment that is produced by electrolytic deposition of nickel on a substrate. Compared to conventional bright nickel, the matt version has a lower reflectivity. This makes it ideal for applications where a reflective finish is undesirable, e.g. instruments or devices where glare is to be avoided. The coating also offers increased corrosion resistance and abrasion resistance.
Protection of high-gloss polishes, dimensional correction to final dimensions.
Electroplated nickel is a versatile and widely used surface coating that is applied to various substrates by electroplating. This coating offers numerous technical advantages that make it a favoured choice in many industrial applications Electrolytic deposition creates a uniform layer that provides corrosion protection, wear resistance and an attractive appearance. This coating is used in various industries and offers a combination of protection and aesthetics for high-quality surfaces
Combination of high wear resistance with low friction and high load-bearing capacity.
AlCrN coating systems offer excellent wear and corrosion protection, high hardness and temperature resistance for demanding industrial applications
Electroless nickel coating with DLC topcoat: Amorphous diamond-like carbon layer - high hardness and low dry friction combined with excellent corrosion protection.
Diamond-like carbon layer with CrN intermediate layer. Resistance to wear with increased load-bearing capacity.
DLC-LF coatings are a special variant of DLC with extremely low coefficients of friction down to 0.05. They reduce wear, energy losses and heat generation, reduce sticking tendency and cold welding. Applications include bearings, gears, seals, pistons, tools and food and medical technology. DLC-LF offers high hardness and good wear protection.
CrN-DLC multilayer coatings offer superior wear and corrosion protection, high hardness and excellent tribological properties for industrial applications
TiCN has a high hardness with good toughness. The low deposition temperature makes it suitable for application on most steels. The coating is very smooth due to the absence of droplets and requires no reworking.
High-performance coating for high wear protection and good corrosion resistance. Ideally suited for coating aluminium.
Dispersion coatings with diamond inclusions serve as extremely high-quality wear protection coatings and improve their properties in terms of tribology.
Electroless nickel coatings offer first-class protection against corrosion and wear. The electroless nickel coating makes the surface robust and durable, with a uniform coating thickness, even with more complex work moulds.
High-performance hard chrome coating with pearl structure for improved wear resistance and corrosion resistance for various industrial applications.
High-quality coating that guarantees very good corrosion protection and high wear resistance. Nickel is applied evenly to the substrate by electrolysis, resulting in a durable and uniform coating. This method is used in various industries, from electronics to the automotive industry, due to its reliability and durability.
In surface technology, the term passivation is used when a protective layer is created on a metallic material. Passivation increases the resistance of the surface to corrosion through a chemical reaction in the passivating acid. The protective layer created in this way is intended to prevent or significantly slow down the corrosion of the base material.
Black chrome layers are decorative coatings that can be deposited with a deep black lustre. Nickel coatings are primarily used as a base for black chrome plating. However, steels, copper and copper alloys as well as nickel alloys can also be black chrome plated directly.
Zinc is probably the most widely used galvanising process. The main application is corrosion protection. Zinc layers are subsequently chromatised, which massively increases the corrosion protection.
Galvanic tinning is used because of the good solderability of the layers, but also offers relatively good corrosion protection, is non-toxic and ecologically harmless
PlanoTek CNB is an innovative coating solution for processing low and non-reinforced thermoplastics (PP, POM, PA6) and thermosets. It is characterised by excellent demoulding properties that make the component removal process considerably easier. The use of PlanoTek CNB reduces adhesion between the plastic and the mould surface, resulting in efficient demoulding. The coating also minimises the formation of unwanted deposits and coatings on the mould surfaces. The use of release agents can be significantly reduced thanks to the excellent non-stick properties of PlanoTek CNB. In addition, the coating offers emergency running properties that provide temporary protection for the tool surfaces in the event of malfunctions. Overall, PlanoTek CNB contributes to optimised production by increasing efficiency, improving quality and increasing profitability.
High-performance hard chrome coating with pearl structure for improved wear resistance and corrosion resistance for various industrial applications.
Wear protection for soft materials, dimensional correction to final dimensions.
Corrosion protection against hand perspiration and humidity, contour protection when processing aggressive plastics, temperature control protection.
Multi-layer system consisting of three different electrochemically produced metallic layers. It was specially developed for mould and tool making to increase service life. TRIODEM is a combined corrosion/wear protection system for sensitive components.
Bright chrome coatings provide an aesthetic surface with a glossy finish and a smooth surface. They improve the appearance of products while providing corrosion protection and durability.
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