Book chapter by Helmholz-Centrum Hereon and Wroclaw University of Science and Technology

SURE2COAT´s project parners, HEREON and WUST, published at the beginning of 2024 a chapter in a new book with the title «Advanced Ceramic Coatings for Energy Applications». It is a publication very related with the work the research institute and the university are doing within SURE2COAT. The book chapter abstract can be read here: Advanced Ceramic Coatings for Energy Applications - 1st Edition | Elsevier Shop.

"This chapter focuses on anticorrosive protective coatings on Al-based elements of​ thermal energy storage (TES) units working with phase change materials (PCM). The main​ challenges of such heat accumulators were discussed, highlighting especially their main​ drawback, which is low thermal conductivity. This feature impairs the charging and​ discharging rates and the overall efficiency of such storage tanks. An opportunity for solving​ this problem was presented – the immersion of spatial metallic structures in the PCM deposit​ that significantly facilitate heat transfer. Nevertheless, working in an aggressive environment​ of molten salts as PCMs requires additional protection of the metal surface against corrosion.​

While giving a brief overview of various protection methods, this work primarily evaluates the​ utilization of plasma electrolytic oxidation (PEO) oxide layers for this purpose. It​ characterizes PEO coatings for aluminum substrates in details and suggests the possible​ strategies to further improve the performance of these layers in TES applications."​

New technology redefines energy efficiency (article)

A EU project is dedicated to advancing energy efficiency through the development of innovative and eco-friendly corrosion protection methods, with the goal of replacing steel with aluminum.

SINTEF coordinates the SURE2COATproject, which stands for "Sustainable Surface Treatments of Complex Shape Components for Transsectorial Industrial Innovation." The project aims to raise the level of surface treatment methods from research to practical application in industry.

The main goal of the project is to address challenges related to corrosion of aluminium alloys in given environments and improve the effect of “gas-water heaters" where the heat-conducting parts of copper may be covered with a water film that reduces heat transfer.

In three very different applications, the project will demonstrate the new production concepts and demonstrate increased sustainability for the entire production, use and reuse chain of aluminium and copper. We want to address the challenges in the following three applications:

• Motor housing for the food industry
• Macro capsules for heat storage
• Gas-water heaters

For the first two applications, the goal is to replace steel as a material with aluminium alloys, while for the copper-based unit (gas-water heaters) we want to change the structure of the surface using laser.

To ensure relevance and efficiency, the project has partnered up with four industry partners, tnamely SIEMENS, BOSCH, MicroArc and COWA. These partners cover each of the three applications, and their insight and expertise will be critical to realising the project's objectives.

What surface treatment methods are we talking about?

1. Sustainable aluminium: SURE2COAT is exploring methods such as plasma electrolytic oxidation (PEO) to create corrosion-resistant surfaces on aluminum alloys. This can replace steel in many applications and significantly reduce its weight, while improving durability and reducing energy consumption.
2. Hybrid materials: Using techniques such as stainless steel spray coating, your product can achieve the best of both worlds. This means preserving aluminium's light weight and good thermal conductivity while using steel's corrosion resistance. This is especially important for the food industry and other sectors with strict standards.
3. Laser precision: SURE2COAT will apply laser structuring techniques to alter copper surfaces at the micrometer level. This optimizes heat transfer and reduces water condensation in gas-water heaters.

The importance of sustainability and climate friendliness
SURE2COAT aims to raise the status of the three coating methods from TRL 3 to TRL 6 (Technology Readiness Level). This involves validating that the methods provide adequate corrosion protection, are environmentally friendly and can be integrated into production processes with reduced energy consumption and environmental impact. This initiative represents:

• New green surface treatment: SURE2COAT seeks to establish sustainable surface treatment methods that will have a positive impact on both the environment and energy consumption.
• Industrial transformation: By integrating these methods into production processes, the project contributes to a reduction in environmental impact and energy consumption compared to existing technologies.
• Commercial use: Upon reaching TRL 6, SURE2COAT are approaching commercial use, and the results have the potential to change industries worldwide

New technology redefines energy efficiency - SINTEF

Manufacturing of Complex shapes, practical Workshop at WUST, May 15-19, 2023

From the 15th to 19th of May, 2023, Wrocław University of Science and Technology (WUST) hosted a workshop in which Sure2Coat partners could delve into the details of manufacturing complex shapes via investment casting technology.

The participants started with a 3D modeling course during which they designed spatial structures. Further days were packed with preparing models, molds, and casting. Additionally, the partners visited MicroArc company, where PEO coatings for proposed solutions in the project will be applied. They also visited the  project partner MicroArc.

See pictures in Workshop WUST.

Sure2Coat is proud to have two new partners: POLIMI and Avio Aero

The new partners are Politecnico di Milano and Avio Aero. They joined consortium in the 2nd trimester of 2024 and will work on a use case related to surface treatment of aluminium parts using cold spray technology.

Research on Latent Heat Storage (LHS) challenges in Phase Change Materials (PCM) presented in EUROCORR 2024

Daniel Blücher, Håvard Wilson, John Erik Lein from SINTEF and Poppy O’Neill from COWA Thermal Solutions showcased the latest Sure2Coat findings on Latent Heat Storage (LHS) challenges in Phase Change Materials (PCM) at EUROCORR 2024 conference on September 4th in Paris, France. The project is pioneering the uptake of aluminium alloys in new sectors involving products with complex shapes, by new sustainable manufacturing methods with lower energy consumption for end users.

Check the video describing the R&D work by the University of Aveiro team and Bosch Portugal

See the video where you can know more about the work which is being done by the University of Aveiro and Bosch Portugal within the framework of SURE2COAT, in close collaboration with the rest of project beneficiaries. Just click on the following link: Optimising laser-based surface treatments to boost heat exchangers in gas water heaters.

SURE2COAT in ManuDays 2024 (Brussels, May, 2024)

𝐓𝐡𝐞 𝐌𝐚𝐧𝐮𝐟𝐚𝐜𝐭𝐮𝐫𝐢𝐧𝐠 𝐏𝐚𝐫𝐭𝐧𝐞𝐫𝐬𝐡𝐢𝐩 𝐃𝐚𝐲𝐬 𝟐𝟎𝟐𝟒, organised by EFFRA in Brussels on May 7th and 8th, was an ideal opportunity to network with other Horizon Europe and Horizon2020 manufacturing projects, and to showcase Sure2Coat alongside two of our sister projects, FABulous Project and BILASURF, who are also advancing research in products with complex functional surfaces.

CIDETEC Surface Engineering and SUPSI were there representing Sure2Coat and it was useful to be able to share discussions and experiences with our sister projects.

CIDETEC Surface Engineering hosted in April 2024 the Surface Treatments Pilot Lines workshop in San Sebastian

The event, organised by the Sure2Coat project and the collaboration of the Bilasurf project, featured the presentations of first-class experts, from leading companies, centres and universities such as Siemens AG, Elsyca, Helmholtz-Zentrum Hereon, Micro-Arc S.C., University of Aveiro and CEIT.

During the two days, attendants visited the adjacent facilities of CEIT and CIDETEC Surface Engineering, both located in San Sebastian, Spain, with various pilot plants for scaling different surface treatments, where live demonstrations were held.

Sure2Coat updated its website with description and links to its EU sister projects.

SURE2COAT works transsectorial to develop new sustainable surface treatments for the future European manufacturing ecosystems. Its sister projects BILASURF, FABulous Project, SYNTECS Project and CLASCO are all under the same work programme and topic and will together impact the development of new products with complex functional surfaces. The projects are funded by the European Commission. Visit the web site of SURE2COAT to learn more.