Industry-compatible complete solutions –

Fraunhofer IWS developed superhard Diamor^® coatings made of tetrahedral amorphous carbon (ta-C) are extremely wear resistant and friction reducing. Thus, they are ideally suited as protective coatings for parts, tools and components under lubricated and non-lubricated operating conditions. The friction reduction directly results in energy or fuel savings for engines and transmissions and therefore offers enormous potential, especially for the automotive industry. Piston rings coated with ta-C have up to 50 percent lower friction values than conventional solutions and thus contribute significantly to reducing carbon dioxide emissions.

The diamond-like carbon coatings are deposited at low temperatures in a vacuum using the specifically developed Laser-Arc^TM process. A laser-induced pulsed vacuum arc discharge generates a plasma of ionized high-energy carbon particles and facilitates a homogeneous coating. For its industrial application, we have developed a modular coating source in cooperation with market leading PVD equipment manufacturers. The Laser-Arc^TM module can be integrated into commercially available PVD coating systems instead of conventional arc and sputter sources. All basic functions of the PVD system thus remain usable and are combined with the new possibilities for depositing ta-C coatings.

In order to keep up the pace in electromobility, battery cell production capacities have to be expanded worldwide. Since the price of an electric vehicle is significantly influenced by the cost of the battery, industry is focusing on both economical and environmentally friendly manufacturing processes. To this end, we have developed DRYtraec^®, a novel process that provides cost-efficient and environmentally friendly manufacturing of battery electrodes. The technology completely excludes the use of toxic solvents and saves the energy- and cost-intensive drying process of the electrode layers. In addition the process can be used to manufacture not only lithium-ion batteries but also novel cell technologies such as lithium-sulfur and solid-state batteries in high quality without the use of solvents.

In the funded project "DryProTex" we developed a worldwide unique prototype system together with German equipment manufacturers and launched it at Fraunhofer IWS. The highlight: The roll-to-roll system enables simultaneous electrode coating on both sides in one step. In the lab, this is already possible on widths of up to 25 centimeters and at speeds of up to ten meters per minute.