Aerosol Deposition

Learn more about the unique advantages of aerosol deposition


What is Aerosol Deposition?

The Aerosol Deposition is a new coating method based on the mechanisms of Room Temperature Impact Consolidation. A special feature and a clear advantage of Aerosol Deposition is that the coating of all material types (ceramics and metals) on all substrate types (metal, glass, ceramics and plastics) is done at room temperature and in low vacuum.

How does the Aerosol Deposition work?

The Aerosol Deposition Process

µm sized particles of the coating material are transported via carrier gas into a coating chamber. There, the particles are accelerated to several 100 m/s and sprayed onto the surface. Particles fracture due to high kinetic energy into fragments and form a layer.

The layer thicknesses formed by Aerosol Deposition are in the range of 1-70 µm.

 Need more details on Aerosol Deposition? Download our technical presentation.

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What are the properties of the coatings applied by Aerosol Deposition?

The layers themselves are very dense and compact, thus showing a high resistance against chemical and mechanical abrasion. Self-evident applications are anti-wear and anti-corrosion protective finishing. Furthermore, films by Aerosol Deposition show extremely good adhesion, thus enabling lasting material combinations that were not possible that easily before. Film properties are usually close to the bulk material properties, e.g. where the electric isolation is concerned.

Comparison of different coating technologies

Compared with all other coating technologies, Aerosol Deposition can be done at low temperature. This is ideal for materials and substrates that are not temperature resistant and enables completely new combinations of coating and substrate.

Aerosol Deposition CVD/PVD Thermal Spray Cold Spray
Material Choice metals, ceramics, composites metals, ceramics, composites metals, ceramics, composites metals, cermets
Deposition Rate high low high very high
Temperature low / room temperature medium / high high medium (~ 300 °C)
Vacuum low vacuum ultra-high vaccum atmospheric atmospheric
Scale-Up medium parts difficult large parts large parts
Thickness 1 – 70 µm ~ 1 µm > 50 µm > 50 µm
Adhesion very good poor good good
Density very dense very dense porous porous
Conformity good very good poor poor
Near-net-shape coating yes CVD: limited (hot)
PVD: no
limited (very hot) limited (hot)
Costs (TCO) low high medium / low medium