Friction, wear, and corrosion are among the biggest hidden cost drivers in industry. They shorten the service life of machines, tools, and components and cause billions in damage year after year. Researchers at the Fraunhofer Institute for Surface Engineering and Thin Films IST in Braunschweig are therefore working on solutions that make technical systems more resilient, durable, and sustainable. The focus is on surfaces and coatings that are specifically tailored to the respective applications of customers and partners.

In doing so, the scientists consider not only individual components but the entire tribosystem – that is, the interaction of materials, surfaces, loads, and movements, for example, in machines. “With our surface engineering technologies, we can reduce wear and corrosion, lower the need for lubricants, and increase the performance of technical components,” explains Dr.-Ing. Jochen Brand, Head of Department Tribology, Corrosion, and Sensor Technology at Fraunhofer IST. “Comprehensive testing methods help us develop the optimal solution for practical application at our industrial customers’ sites.”

A current example is high-performance boride coatings, which are the subject of intensive research at Fraunhofer IST. They protect tools and components against high temperatures, severe friction, and aggressive environmental conditions, thereby significantly extending their service life. With an expanded research infrastructure, the institute can now cover the entire process chain – from surface treatment and coating to real-world stress tests – at its main site in Braunschweig.

In addition to surface protection, sensor technology also plays an important role. Thin functional coatings can, for example, measure temperature and wear directly during operation in the main stress zone. The resulting data enable continuous monitoring of machines and tools, making maintenance more predictable and helping to prevent unplanned downtime. This not only improves the efficiency of manufacturing processes but also enhances safety and sustainability.

In addition to application-specific tribosystem and sensor solutions for various industries, Fraunhofer IST also develops cost-effective, flexible production systems tailored to the needs of individual customers to enable rapid implementation suitable for series production.