Basic parameters for the coating process (PRISMA)

Status: completed, 29.01.2019 – 31.10.2023

The spread of electric vehicles is increasing and their market share is growing rapidly. However, there are still limitations to electric mobility in terms of range compared to conventional combustion engines. In addition to larger battery capacities, improvements can be achieved through increased efficiency and lower vehicle weight.

To this end, the Leibniz Institute for Plasma Research and Technology (INP) has conducted research in the joint project 'Integrative Layer Heating Module' together with the partners

• Webasto Thermo & Comfort SE; Webasto Neubrandenburg GmbH
• Fraunhofer Institute for Large Structures in Production Engineering IGP
• Welding Technology Training and Testing Institute Mecklenburg-Vorpommern GmbH

on technical solutions for electric vehicle heaters. The core component is a heating module that uses thin layer structures for heating. This allows the high-voltage components in electric vehicles to be used effectively at their optimal operating point while saving moving mass. The introduction of such heating modules thus brings both economic and ecological advantages.

Essential for the quality of the product is the production of thin ceramic and metallic layers. These are applied by means of atmospheric pressure plasma spraying. Although this process has already proven itself for years in many areas of thin-film technology, its practical application in industrial manufacturing processes raises questions regarding the homogeneity of the layer thickness to be achieved, the utilisation of the raw material, the material properties to be achieved, the process stability over time or even the life cycle of the plasma torches.

This is where INP comes in with its many years of expertise in the field of plasma diagnostics and plasma technology. Optical methods (spectroscopy and high-speed photography) are used to characterise the plasma properties of the plasma spraying systems involved in production and to visualise layer growth. The experimental findings are complemented by numerical simulations and combined to form a well-founded picture of the plasma process.

From process monitoring to targeted process control, the project contributes to producing products of a consistently high quality and to making the manufacturing process more effective by reducing maintenance.