Coatings Technology

by DURIT

Coatings

The term "coatings" describes a core group of manufacturing processes that attach a firmly adhering layer of an amorphous material to the surfaces of a component part. These processes can be differentiated as chemical, mechanical, thermal and thermo-mechanical. The english word "coating" is often used as the widely accepted trade term in other languages as well.

DURIT COATINGS—WEAR PROTECTION AND BEST PERFORMANCE

Even in the coating market we take a leading role. Our processes stand for technological innovation and increase the performance and service life of parts, tools and components. The possibilities for improvement and optimization with DURIT Coatings are nearly limitless.

TARGETED OPTIMIZATION OF PERFORMANCE AND ENDURANCE

Surface optimization that creates added value:

REDUCTION
of abrasion, erosion and friction

INCREASE
of resistance (wear and corrosion)

IMPROVEMENT
conductivity and isolation (electrical, thermal)

CREATION
of bio-compatibility

High-performance coatings by DURIT enhance wear resistance and extend the service life of tools, components, and carbide parts.

DURIT coatings deliver optimized surface protection, improving the durability and efficiency of precision-engineered parts.

With advanced coating technologies, DURIT boosts performance and reliability in demanding industrial applications.

Innovative DURIT coatings support long-term functionality and help maximize output under extreme operating conditions.

Coatings Processes by Durit

» Laser Cladding
» Thermal Spray Coatings: HVOF, APS, EAWS
» PVD/PACVD Coatings
» CVD Coatings

DURIT coatings unlock peak performance and unmatched durability for tools and components in high-stress environments.

Advanced DURIT coatings offer superior wear protection – engineered to push the limits of performance and endurance.

Thermal spray Coatings by Durit

Using effective processes we create custom-tailored solutions that increase the service-life of parts and components: the improvement of surface properties is developed and implemented by our experts individually and specific to each application.

WE SOLVE YOUR WEAR PROBLEM

This applies to existing production processes as well. Wear tracks and potential failure root causes are analyzed—including all pertinent operating parameters, such as temperature, pressure, adjacent parts or the processed medium. Thermal coatings by DURIT are the most effective opporunity to greatly increase operating performance.

MEETING THE MOST CHALLENGING DEMANDS

LASER CLADDING

» Alloys

Weldable powders (carbides and metal alloys) comparable to Stellite^®, Tribaloy^®, Colmoloy^®, Hastaloy^®, Inconel^® or similar

HVOF

High Velocity Oxygen Fuel

» Carbides

WC/Co

WC/Co-Cr

WC/Ni

WC/NiCr

WC/NiCrBSiFe

Cr₂C₃/NiCr

APS

Atmospheric Plasma Spraying

» Ceramics

Al₂O₃

TiO₂

Al₂O₃/TiO₂

Cr₂O₃

Cr₂O₃/TiO₂

ZrO₂/MgO

ZrO₂/Y₂O₃

EAWS

Electric Arc Wire Spraying

» Metals

NiCr

NiCrMo

NiCrAIY

Additional coating materials on request

Laser cladding

Laser deposition welding

Laser cladding

With laser cladding the surface of the workpiece is melted locally. Motion of the laser optics and powder nozzle create weld-beads on the workpiece to be coated. The laser creates a weld pool on its surface. Metal powder is automatically inserted through a nozzle. Applied side-by-side, defined areas can be functionally coated and applied on top of each other to increase layer thickness so that part shapes can be created or repaired.

FOR THE CREATION OF HIGH VALUE COATINGS AND STRUCTURES

PROPERTIES

Ø Adhesive pull strength: > 300 MPa
Ø Porosity: 0%
Ø Layer Thickness: 0.2 to 5 mm and more

Laser cladding at DURIT enables precise surface melting and targeted application of metal powder to build high-value protective layers.

DURIT uses advanced laser cladding to deposit metal powder exactly where needed – for repairing, strengthening or building up components.

Layer by layer, DURIT laser cladding enables customized surface structures and functional coatings with maximum precision.

Laser cladding Process

Laser cladding is a precision welding process where metal powder is fused onto the surface using a laser, creating wear-resistant coatings or restoring component geometry.

Laser cladding Overview

PROPERTIES:
Very good layer adhesion due to molten metal bonding, partial coating as well as complex geometries possible, precise line detail with elaborate part shapes, development of very fine micro-structures, limited heat transfer. Very high adhesive pull strength.

SPECIAL TECHNICAL FEATURES:
Completely sealed surface, with a porosity of 0%, therefore gas-tight or diffusion-tight. Very high adhesive pull strength.

TYPICAL APPLICATIONS:
Machine parts such as shafts, guides, rollers, wear strips etc., valve parts, pump parts such as bearings, compressor blades, housing interiors that require partial wear protection.

APPLICABLE COATING MATERIALS:
All meltable metals in powder form such as Inconel, Hastelloy, Stellite etc. as well as carbides with different binders.

LAYER THICKNESS
0.2–5 mm and more.

Laser cladding applies metal powder with precision to create wear-resistant layers and extend the lifespan of industrial components.

The laser cladding process restores part geometry and builds protective coatings, ideal for high-performance applications.

Advanced laser cladding technology at DURIT enhances surface durability and function through targeted metal powder deposition.

DURIT uses laser cladding to apply protective layers that improve performance and reduce downtime in industrial equipment.

HVOF

High Velocity Oxi-Fuel

Laser cladding combines precision engineering with advanced laser control to create functional surfaces layer by layer – a fusion of science and performance.

Witness the power of laser cladding: where metal powder becomes part of the component and high-tech surfaces are created with light and accuracy.

HVOF

With high-velocity flame spraying a fuel/oxygen mixture is continuously combusted at very high pressure. A powdery spray-additive is injected into the central axis. The pressure created by the gas/oxygen mixture in the combustion chamber and the downstream expansion nozzle create a very high flow velocity. This way the spray particles are accelerated to supersonic speed and applied to the workpiece. Our coating experts are therefore able to apply very dense layers to enhance the piece with optimal wear properties.

FOR THE CREATION OF DENSELY SEALED SURFACES

PROPERTIES

Ø Adhesive pull strength: > 80 MPa
Ø Porosity: 0.5% to 1%
Ø Layer Thickness: 100 to 500 μm

HVOF spraying uses supersonic gas velocities to apply dense, wear-resistant coatings to industrial components.

HVOF Process

Through high-pressure combustion and a focused spray jet, HVOF enables the precise application of high-performance coatings.

DURIT’s HVOF technology creates tightly sealed coatings with outstanding wear protection and extended service life.

HVOF Overview

PROPERTIES:
Very good wear protection against abrasion and erosion as well as good corrosion resistance.

SPECIAL TECHNICAL FEATURES:
Relatively dense, with a porosity of 0.5–1%, therefore gas-tight (diffusion-tight)

TYPICAL APPLICATIONS:
machine parts such as shafts, guides, rollers, wear strips et. al., valve parts, pump parts, impellers

APPLICABLE COATING MATERIALS:
WC/Co, WC/Co-Cr, WC/Ni, WC/NiCr, WC/NiCrBSiFe, Cr₂C₃/NiCr

LAYER THICKNESS:
0.1–0.5 mm

The HVOF process delivers strong, low-porosity coatings with superior adhesion – ideal for enhancing surface performance and reducing wear.

HVOF coating creates extremely dense and well-bonded surface layers, providing excellent wear resistance and long-term durability.

APS

Atmospheric Plasma Spraying

APS technology turns plasma energy into precision: molten particles form advanced coatings that protect and enhance critical components.

With APS, DURIT creates dense, structured coatings – a process where technology and temperature combine to build durable surfaces.

APS

With the APS process, or “plasma spraying”, a powdery spray-additive is melted inside or outside the spray gun by a plasma beam and flung onto the surface of the workpiece. The most flexible of all thermal spray processes allows excellent handling and control to create optimal layer thicknesses and surface properties with regard to porosity and hardness.

FOR HIGHEST QUALITY AND DURABLE STABILITY

PROPERTIES

Ø Adhesive pull strength: 20 to 50 MPa
Ø Porosity: 4% to 8%
Ø Layer Thickness: 200 to 1,000 μm

APS-coated components offer reliable surface protection, improved thermal resistance, and extended service life under extreme conditions.

With APS coatings, DURIT provides high-quality surfaces that ensure durability, stability, and efficiency in demanding applications.

APS Process

APS uses a high-temperature plasma jet to melt powder particles and apply dense coatings with outstanding durability.

Atmospheric plasma spraying transforms energy into engineered surface layers – precise, reliable, and built for extremes.

APS Overview

PROPERTIES:
Good wear protection against abrasion and erosion, good corrosion resistance, good thermal, electrical or magnetic isolation, biocompatibility.

SPECIAL TECHNICAL FEATURES:
Relatively porous, with a porosity of 4–8%, therefore not gas-tight or diffusion-tight

TYPICAL APPLICATIONS:
Valve inserts, pump parts (e.g. bearing housings), pistons especially with chemical demands

APPLICABLE COATING MATERIALS:
Ceramics like Al₂O₃, TiO₂, Al₂O₃/TiO₂, Cr₂O₃, Cr₂O₃/TiO₂, Cr₂O₃/SiO, ZrO₂/CaO, ZrO₂/MgO, ZrO/YO/CeO, ZrO₂/Y₂O₃

LAYER THICKNESS:
0.2–0.5 mm (in middle sometimes up to 1 mm possible)

APS coatings offer strong protection for components under stress, delivering heat- and wear-resistant surfaces for top industrial performance.

With atmospheric plasma spraying, DURIT enhances product surfaces with dense, durable layers that resist abrasion, heat, and corrosion.

EAWS

Electric Arc Wire Spraying

In a storm of sparks, electric arc spraying delivers powerful coatings – where technology meets raw industrial force.

EAWS

With electric ARC wire spraying the spray additive is continually melted in the center of an acetylene/oxygen flame. Aided by a vaporizer gas, i.e. compressed air or nitrogen, droplet-shaped spray particles are separated and flung onto the primed surface of the workpiece. This process allows high spray rates with low gas consumption. EAWS wire spraying creates surface layers with an average porosity of about 3% and an adhesive pull strength of 40 MPa for greatly increased wear protection.

FOR WORKPIECE SURFACES THAT HAVE TO LAST LONGER

PROPERTIES

Ø Adhesive pull strength: 15 to 40 MPa
Ø Porosity: 3%
Ø Layer Thickness: 200 to 5,000 μm

EAWS wire spraying creates smooth, wear-resistant coatings with low porosity and high bond strength – perfect for surfaces built to endure.

Electric arc wire spraying enables dense, uniform coatings with excellent adhesion and minimal gas use, protecting parts that face extreme wear.

With fine droplet distribution and strong pull strength, EAWS produces surface layers that combine technical precision with long-term performance.

EAWS delivers beautiful, technically superior surfaces with high spraying rates and reduced gas consumption – ideal for industrial longevity.

EAWS Process

Electric arc wire spraying uses a continuous electric arc to melt wire, which is atomized by gas and applied as a coating to the workpiece surface.

EAWS Overview

PROPERTIES:
Good wear protection against abrasion and erosion, good corrosion resistance.

SPECIAL TECHNICAL FEATURES:
Medium porosity of about 3%

TYPICAL APPLICATIONS:
Machine parts such as shafts, guides and valve parts

APPLICABLE COATING MATERIALS:
Metals such as Mo99.9+, Cu5Al, Ni₂0Cr, Sn7, 5Sb3,5Cu, AISI420, AISI316, AISI304, Liga C-276, Stainless Steels

LAYER THICKNESS:
0.2–0.8 mm (in middle sometimes up to 5 mm possible)

The EAWS process allows cost-efficient surface coating with excellent adhesion and minimal gas usage, ideal for industrial applications.

Electric arc wire spraying applies durable coatings with high bond strength and low porosity – optimized for wear protection and long service life.

PVD/PACVD-Coatings

PVD and CVD coatings deliver ultra-thin, hard surface layers with excellent adhesion and wear resistance – combining visual perfection with technical precision.

With PVD/CVD technology, DURIT creates visually refined, high-performance surfaces that offer maximum durability and chemical stability.

PVD/PACVD

PVD and PACVD processes are frequently used with metal cutting and shaping tools—especially to increase service life. With PVD and PACVD processes—specifically tailored to the respective application—good wear resistance and high hardness can be achieved.

Both processes offer a wide range of options for successfully improving individual material properties with regard to:

» WEAR PROTECTION
» OXIDATION RESISTANCE
» CORROSION RESISTANCE
» BIOCOMPATIBILITY

Aesthetic surface enhanced by PVD/PACVD technology for improved wear protection and long-lasting performance.

Refined metallic surface showing the benefits of PVD and PACVD processes in demanding industrial applications.

PVD/PACVD Coatings for all Industries and Applications

PVD/PACVD

The PVD process is based on the release of metallic layer components such as titanium, aluminum, zirconium or chromium. They are transformed into their gaseous state using a full vacuum and their particles are transported towards the workpiece through electrical currents and plasma. By adding a reactive component, such as nitrogen or carbon, they attach firmly to the surface.

FOR STRONG, DURABLE BOND

The PVD process enables the separation of very thin, yet also very hard, firmly adhering layers. The most common are: titanium-nitride coatings, titanium-aluminum-nitride coatings, chromium-nitride coatings as well as titanium-carbide coatings. All PVD coatings made by DURIT deliver convincing performance with their outstanding adhesive qualities. DURIT PVD coatings minimize wear permanently.

FOR OUSTANDING, WEAR OPTIMIZING ADHESIVE STRENGTH

PROPERTIES

Ø Maximum Part size: 400 x 800 mm, to max. 250 kg
Ø Coating tempature: 450 °C or less (to 180 °C)
Ø Layer Thickness: 3–5 μm

PVD-coated surface showing strong, wear-resistant bonding of titanium or chromium-based layers under vacuum and plasma conditions.

High-performance coating created through PVD technology using metallic vapors like Ti, Al, or Cr with nitrogen or carbon for optimal adhesion.

Durable thin-film layer applied by PVD – a vacuum-based process with plasma activation for maximum wear protection and bond strength.

Plasma-enhanced PVD coating with strong adherence and outstanding surface performance using reactive gases and metallic elements.

PVD Process

Physical vapor deposition (PVD) uses vacuum and plasma to form wear-resistant, firmly bonded coatings with excellent surface properties.

PACVD Process

Plasma-assisted CVD combines chemical vapor deposition with plasma excitation to create hard, firmly bonded layers on complex surfaces.

PVD/PACVD Overview

PROPERTIES:
Good glide capacity, low coefficient of friction, high hardness and corrosion resistance.

MATERIALS TO BE COATED
All Metals, Ceramics, Plastics, Glass.

LAYER THICKNESS
3–5 μm. Thicker layers can be created, but tend to develop cracks due to higher internal stress.

COATING TEMPERATURES
450 °C or below (to 180 °C), which allows coating of collared tools. Soldered parts can also be coated, but a special solder must be used.

MAXIMUM PART SIZE
Ø 400 x 800 mm, to max. 250 kg.

SPECIAL TECHNICAL FEATURES
Bores are only completely coated to a depth of 1 x D. At lower depths, layer thickness decreases.

Technically optimized and visually striking surface treated with PVD/PACVD for enhanced durability and minimal friction.

TYPICAL APPLICATIONS:

DRAWING TOOLS
Reduction of friction, protection from aggressive mediums.

PUNCHING TOOLS
Increased stability of cutting edge, protective layer to avoid galling.

SHAPING TOOLS
Reduction of friction, protective layer to avoid galling.

BEARING SLEEVES
Reduction of friction, protection from aggressive mediums, biocompatibility

CUTTING TOOLS
Increased stability of cutting edge, reduction of friction.

INJECTION MOLDING TOOLS
Increased wear resistance and reduced adhesion tendency.

Modern component with PVD/PACVD/CVD coating – high surface hardness, low friction and a visually refined, functional finish.

Aesthetic high-tech surface created through thin-film coating with excellent glide properties and strong corrosion resistance.

Advanced vacuum coating with elegant finish – wear-resistant layer (3–5 μm) suitable for metals, plastics, ceramics, and glass.

CVD-Coatings

Detailed view of Chemical Vapor Deposition in action, applying uniform coatings for advanced surface performance in technical applications.

CVD process close-up showing gas-phase deposition of hard, wear-resistant layers on complex surfaces – engineered for durability and precision.

CVD

From the heated surface of a substrate a solid component is separated through a chemical reaction in the gas phase. This takes place in a vacuum chamber. The gas created spreads out as a fine mist within the chamber and finally condenses on the workpieces to be coated. Due to the stress distribution and particle size the smallest contours and shapes can be coated.

ADDED VALUE FOR INDUSTRIES, SUCH AS MEDICAL TECHNOLOGY, AUTOMOTIVE INDUSTRY, MECHANICAL ENGINEERING AND MORE

PROPERTIES

Ø Maximum Part size: 600 x 800 mm, to max. 330 kg
Ø Coating temperature: above 1,000 °C
Ø Layer thickness: 5–12 μm

CVD-coated component with smooth, uniform surface – optimized for wear resistance, hardness, and long-term durability.

High-performance product with advanced CVD coating, combining technical precision and a clean, modern finish.

CVD Process

CVD Overview

PROPERTIES:
Good glide capacity, low friction coefficient, high hardness.

MATERIALS TO BE COATED
All temperature resistant metals, ceramics.

LAYER THICKNESS
5–12 μm, even thicker layers can be created, but tend to develop cracks due to higher internal stress.

COATING TEMPERATURES
Only solid, single parts can be coated. A special case are hardened steels—their hardening takes place at the same time as the coating. At over 1,000°C armored tools can no longer be coated.

MAXIMUM PART SIZE
~ Ø 600 x 800 mm, to max. 330 kg.

SPECIAL TECHNICAL FEATURES
Bores are completely coated, meaning complete layer thickness throughout the entire bore depth, very good adhesion to the substrate.