{"id":17257955,"date":"2026-11-04T10:00:00","date_gmt":"2026-11-04T09:00:00","guid":{"rendered":"https:\/\/felss.com\/?post_type=blog&p=17257955"},"modified":"2026-11-12T11:18:04","modified_gmt":"2026-11-12T10:18:04","slug":"only-a-look-at-the-surface","status":"publish","type":"blog","link":"https:\/\/felss.com\/en\/blog\/only-a-look-at-the-surface\/","title":{"rendered":"Only a look at the surface"},"content":{"rendered":"\n

Surface technology: The underestimated key technology of industrial value creation<\/h2>\n\n\n\n

In the public perception, surfaces are often reduced to “finish” \u2013 to appearance, colour or corrosion protection. In reality, they determine friction, wear, service life, electrical conductivity, biocompatibility or temperature resistance. They are therefore functional system components.<\/p>\n\n\n\n

Especially in the mobility industry \u2013 from electric drives to fuel cells to autonomous sensor platforms \u2013 surface technology is not an add-on, but a performance enabler. Anyone who underestimates them is wasting efficiency, durability and differentiation potential.<\/p>\n\n\n\n

Scientific Classification of Surface Processes<\/h2>\n\n\n\n

In materials science, surface processes are systematically classified \u2013 primarily according to the principle of action and depth of intervention. Among other things, the classification according to DIN 8580 (manufacturing processes) as well as thermodynamic and physicochemical mechanisms is decisive.<\/p>\n\n\n\n

1. Mechanical processes<\/h3>\n\n\n\n

Principle:<\/strong> Removal or plastic deformation of the edge zone
Examples<\/strong>: Grinding, polishing, blasting, shot blasting
Objective: <\/strong>Roughness, residual compressive stresses, fatigue resistance<\/p>\n\n\n\n

2. Thermochemical surface layer treatment<\/h3>\n\n\n\n

Principle:<\/strong> Diffusion of atoms into the edge zone at elevated temperature
Examples:<\/strong> Nitriding, case hardening, carbonitriding
Objective:<\/strong> Hardness, wear resistance, fatigue resistance<\/p>\n\n\n\n

3. Chemical and electrochemical processes<\/h3>\n\n\n\n

Principle:<\/strong> Deposition by chemical reaction or electrolytic processes
Examples:<\/strong> electroplating, electroless nickel (EN), anodizing
Objective:<\/strong> Anti-corrosion, conductivity, decorative effects<\/p>\n\n\n\n

4. Physical and plasma-assisted thin-film processes<\/h3>\n\n\n\n

Principle:<\/strong> Gas Vapor Deposition or Plasma Activation
Examples:<\/strong> PVD, CVD, DLC, Plasma Nitriding
Aim:<\/strong> Friction Reduction, Barrier Properties, High-Temperature Stability<\/p>\n\n\n\n

5. Organic coatings<\/h3>\n\n\n\n

Principle:<\/strong> Polymer-based protective or functional coatings
Examples:<\/strong> Painting, powder coating, laminating
Objective:<\/strong> Corrosion, UV stability, design<\/p>\n\n\n\n

6. Additive and hybrid processes<\/h3>\n\n\n\n

Principle:<\/strong> Combination of several mechanisms (e.g. laser cladding + PVD)
Goal:<\/strong> Function integration, repair, lightweight construction<\/p>\n\n\n\n

Overview of the most important surface processes<\/h2>\n\n\n\n
Procedure<\/th>Category<\/th>Typical layer thickness<\/th>Improved properties<\/th>Typical Applications<\/th><\/tr><\/thead>
Painting<\/td>Organic<\/td>20\u2013200 \u03bcm<\/td>Korrosion, UV, Design<\/td>Body, Interior<\/td><\/tr>
Powder coating<\/td>Organic<\/td>60\u2013150 \u03bcm<\/td>Mechanical robustness<\/td>Chassis components<\/td><\/tr>
Electroplating (Zn, Ni, Cr)<\/td>Electrochemical<\/td>5\u201330 \u03bcm<\/td>Corrosion, conductivity<\/td>Screws, Connectors<\/td><\/tr>
Chemisch Nickel (EN)<\/td>Chemical<\/td>5\u201350 \u03bcm<\/td>Uniformity, hardness<\/td>Precision parts<\/td><\/tr>
Anodizing<\/td>Electrochemical<\/td>5\u201325 \u03bcm<\/td>Oxidation protection, insulation<\/td>Aluminum housing<\/td><\/tr>
Nitriding<\/td>Thermochemisch<\/td>0.1\u20130.6 mm<\/td>Hardness, fatigue resistance<\/td>Gears<\/td><\/tr>
Case hardening<\/td>Thermochemisch<\/td>0.5\u20132 mm<\/td>Wear, core toughness<\/td>Transmission Components<\/td><\/tr>
PVD (TiN, CrN)<\/td>Physical<\/td>1\u20135 \u03bcm<\/td>Friction reduction<\/td>Tools, injection systems<\/td><\/tr>
CVD<\/td>Chemical<\/td>5\u201320 \u03bcm<\/td>High-temperature stability<\/td>Turbines<\/td><\/tr>
DLC<\/td>PVD\/CVD<\/td>1\u20133 \u03bcm<\/td>Extremely low friction<\/td>Piston Rings<\/td><\/tr>
Plasma nitriding<\/td>Plasma<\/td>0.1\u20130.5 mm<\/td>Wear, fatigue<\/td>E-drive components<\/td><\/tr>
Thermal spraying<\/td>Thermal<\/td>50 \u03bcm\u20132 mm<\/td>Wear, insulation<\/td>Fuel cells<\/td><\/tr>
Laser deposition welding<\/td>Additive<\/td>>500 \u03bcm<\/td>Repair, Structure<\/td>Large components<\/td><\/tr>
Laminating<\/td>Organic\/Hybrid<\/td>variabel<\/td>Barrier, Design<\/td>Interior, battery housing<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n

What properties are created or improved?<\/h2>\n\n\n\n

Surface treatments affect:<\/p>\n\n\n\n

    \n
  • Tribology:<\/strong> Coefficient of friction (DLC <0.1 possible)<\/li>\n\n\n\n
  • Corrosion resistance:<\/strong> Zinc-nickel >1000 h salt spray<\/li>\n\n\n\n
  • Fatigue resistance:<\/strong> shot blasting induces residual compressive stresses<\/li>\n\n\n\n
  • Electrical conductivity:<\/strong> silver or copper electroplating<\/li>\n\n\n\n
  • Thermal Barrier:<\/strong> Ceramic CVD Layers<\/li>\n\n\n\n
  • Chemical resistance:<\/strong> PTFE, fluoropolymers<\/li>\n\n\n\n
  • Biocompatibility:<\/strong> Titanium Oxide Layers<\/li>\n<\/ul>\n\n\n\n

    The scientific basis for this is provided by tribological and materials science studies, including those published in Surface & Coatings Technology (Elsevier) and work by the Fraunhofer Institute for Surface Engineering and Thin Films IST.<\/p>\n\n\n\n

    Market and industry development<\/h2>\n\n\n\n

    According to data from MarketsandMarkets, the global surface treatment market will grow to over USD 160 billion by 2030 (CAGR ~6%). The ZVO \u2013 Central Surface Technology Association reports that e-mobility, hydrogen and power electronics in particular are growth drivers.<\/p>\n\n\n\n

    \"Bar
    Figure 1: Development of the global surface treatment market (Source: MarketsandMarkets 2024 Report, ZVO Industry Figures 2023)<\/figcaption><\/figure>\n\n\n\n
    \"Surface
    Figure 2: Growth drivers by sector<\/figcaption><\/figure>\n\n\n\n

    Key projects and industrial players<\/h2>\n\n\n\n

    Automotive & Mobility Industry<\/h3>\n\n\n\n

    Volkswagen AG is increasingly relying on plasma-nitrided transmission components in electric drives to increase efficiency.<\/p>\n\n\n\n

    BMW Group uses DLC coatings in high-pressure injection systems.<\/p>\n\n\n\n

    Tesla, Inc. relies on highly corrosion-resistant aluminum surfaces for battery housings.<\/p>\n\n\n\n

    Fuel Cells & Hydrogen<\/h3>\n\n\n\n

    Bosch is developing coated bipolar plates for fuel cells to reduce contact resistance.<\/p>\n\n\n\n

    thyssenkrupp nucera uses special coatings to increase the service life of electrolysis cells.<\/p>\n\n\n\n

    Robotics & High-Tech<\/h3>\n\n\n\n

    KUKA AG integrates wear-resistant coatings in joint modules for longer maintenance intervals.<\/p>\n\n\n\n

    ABB Ltd. is focusing on corrosion-resistant surfaces in collaborative robots for the food industry.<\/p>\n\n\n\n

    Innovative companies in surface technology<\/h2>\n\n\n\n
      \n
    • Oerlikon Balzers \u2013 PVD\/DLC Marktf\u00fchrer<\/li>\n\n\n\n
    • Bodycote \u2013 Thermochemical processes<\/li>\n\n\n\n
    • Ionbond \u2013 Thin-film solutions<\/li>\n\n\n\n
    • Hauzer Techno Coating \u2013 PVD-Anlagen<\/li>\n\n\n\n
    • Plasmatreat GmbH \u2013 Atmospheric Pressure Plasma<\/li>\n<\/ul>\n\n\n\n

      Technological innovations<\/h2>\n\n\n\n

      1. Functional Multilayer DLC<\/h3>\n\n\n\n

      Improves adhesion, friction and temperature resistance.<\/p>\n\n\n\n

      2. Plasma activation at room temperature<\/h3>\n\n\n\n

      Allows coating of temperature-sensitive materials.<\/p>\n\n\n\n

      3. Nanostructured layers<\/h3>\n\n\n\n

      Targeted control of wettability (lotus effect).<\/p>\n\n\n\n

      4. Smart Coatings<\/h3>\n\n\n\n

      Self-healing coatings, sensory coatings for condition monitoring.<\/p>\n\n\n\n

      Scientifically documented in papers of the Max Planck Institute for Iron Research and in Progress in Materials Science, among others.<\/p>\n\n\n\n

      Surface technology is not a cost factor \u2013 it is a performance multiplier<\/h2>\n\n\n\n

      In many OEM organizations, surface technology is still assigned to purchasing or production \u2013 not to development. This is strategically wrong.<\/p>\n\n\n\n

      Friction reduction of a few percentage points is decisive for the range of electric drives. Corrosion resistance determines warranty and recall costs.<\/p>\n\n\n\n

      If you only optimize “costs per square meter” instead of looking at system performance, you will lose touch technologically.<\/p>\n\n\n\n

      Voices from the industry<\/h2>\n\n\n\n

      “The service life of our components is largely determined by tribological optimization.” \u2013 Statement from technical white papers from Oerlikon Balzers.<\/p>\n\n\n\n

      In several publications, the Fraunhofer-Gesellschaft emphasizes that surfaces in e-mobility applications enable efficiency increases in the low single-digit percentage range \u2013 which is systemically significant.<\/p>\n\n\n\n

      Outlook<\/h2>\n\n\n\n

      With increasing electrification, higher power densities and new material combinations, the importance of functionalized surfaces is growing exponentially.<\/p>\n\n\n\n

      The next evolutionary stage is integrated multifunctional layers that combine mechanical, electrical and sensory properties.<\/p>\n\n\n\n

      The mobility industry is faced with a decision:<\/p>\n\n\n\n

      Will surface technology continue to be regarded as a necessary production step \u2013 or as a strategic innovation lever?<\/p>\n\n\n\n

      Call to Action<\/h3>\n\n\n\n

      How do you see that?<\/p>\n\n\n\n

      Is surface technology already strategically anchored in your organization \u2013 or is it still a “finishing topic”?<\/p>\n\n\n\n

      I look forward to your well-founded perspectives and experience in development, purchasing and production.<\/p>\n","protected":false},"author":11,"featured_media":17257984,"template":"","meta":{"_acf_changed":false,"_et_pb_use_builder":"","_et_pb_old_content":"","_et_gb_content_width":"","footnotes":"","_ppma_block_editor_authors":""},"categories":[],"ppma_author":[293],"class_list":["post-17257955","blog","type-blog","status-publish","has-post-thumbnail","hentry"],"acf":[],"_links":{"self":[{"href":"https:\/\/felss.com\/en\/wp-json\/wp\/v2\/blog\/17257955","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/felss.com\/en\/wp-json\/wp\/v2\/blog"}],"about":[{"href":"https:\/\/felss.com\/en\/wp-json\/wp\/v2\/types\/blog"}],"author":[{"embeddable":true,"href":"https:\/\/felss.com\/en\/wp-json\/wp\/v2\/users\/11"}],"version-history":[{"count":3,"href":"https:\/\/felss.com\/en\/wp-json\/wp\/v2\/blog\/17257955\/revisions"}],"predecessor-version":[{"id":17258042,"href":"https:\/\/felss.com\/en\/wp-json\/wp\/v2\/blog\/17257955\/revisions\/17258042"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/felss.com\/en\/wp-json\/wp\/v2\/media\/17257984"}],"wp:attachment":[{"href":"https:\/\/felss.com\/en\/wp-json\/wp\/v2\/media?parent=17257955"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/felss.com\/en\/wp-json\/wp\/v2\/categories?post=17257955"},{"taxonomy":"author","embeddable":true,"href":"https:\/\/felss.com\/en\/wp-json\/wp\/v2\/ppma_author?post=17257955"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}