Your pain points
- our solutions
Facts first
Across industries, extreme temperatures, wear, corrosion, and material adhesion continue to limit equipment performance, operational efficiency, component lifetime, and product quality. Conventional coatings often struggle under sustained thermal and mechanical stress – driving maintenance, downtime, lifecycle costs, and process variability.
ThermaSiC is engineered to perform where conventional solutions reach their limits. By enabling silicon carbide in thermal spray applications, Seram Coatings introduces a new generation of high-performance, heavy-metal-free surface solutions.
With broad cross-sector relevance, ThermaSiC addresses critical challenges in metal processing, hollow glass manufacturing, aerospace, oil and gas, and heavy industry – where wear, thermal degradation, and aggressive operating conditions impact both equipment reliability and consistent product quality.
Through continuous innovation, industrial validation, and application-driven collaboration, Seram Coatings is advancing the boundaries of modern surface engineering.
Metal & Aluminium
Metal processing industries operate under some of the most demanding industrial conditions, where extreme temperatures, aggressive environments, and continuous mechanical stress define performance requirements. Ensuring reliability, efficiency, and durability across these processes remains a constant challenge as operational demands and regulatory pressures continue to increase.
Extreme process temperatures and corrosive operating environments Maximum service temperatures >1400 °C with excellent chemical stability against molten metals and slags enabling substitution of base materials.
ThermaSiC Solves Critical Pain Points in Metal Processing:
Read more
Severe wear, galling, and material build-up in annealing and galvanizing lines
Low-friction, anti-wetting ThermaSiC surface technology with molten aluminum contact angles of ~140–152° reducing adhesion and build-up.
Surface degradation under thermal cycling and fluctuating process conditions
Thermal shock resistance proven up to 800 °C combined with high coating integrity and strong substrate adhesion.
Balancing wear protection with operational efficiency in metal-contact applications
Engineered for adhesive and mixed-wear environments, offering a customizable friction coefficient together with industrial-level hardness.
High maintenance frequency and costly component replacement cycles
Engineered for long-term durability through optimized wear and corrosion resistance, under stable ceramic chemistry.
Growing ESG and regulatory pressure to reduce hazardous substances and CO₂ footprint
Heavy-metal-free coating platform supporting longer component lifecycles, reduced material waste, and more sustainable industrial operation.
Glass Industry
In glass container manufacturing, continuous swabbing remains a persistent source of inefficiency in the hot end. Conventional moulds and tooling require frequent application of graphite-based lubricants to prevent molten glass adhesion, ensure release, and protect forming surfaces. While necessary, swabbing interrupts production, increases defect and scrap rates, contaminates the work environment, and accelerates wear of critical components.
Read more
ThermaSiC is designed to eliminate this dependency. The silicon carbide–based ceramic coating combines high wear resistance with low-friction, non-stick performance against molten glass, maintaining stable surface properties under continuous thermal cycling.By minimizing glass adhesion and preserving tooling geometry, ThermaSiC enables consistent release behaviour, stable heat transfer, and more predictable forming conditions. This extends the service life of moulds, neck rings, plungers, bottom plates, tongs, and other hot-end components, while supporting uninterrupted production and improved process stability.
Eliminating swabbing reduces scrap, increases uptime, lowers maintenance demand, and improves overall equipment effectiveness (OEE). At the same time, removing graphite-based lubricants reduces workplace contamination, enhances operator safety, supports REACH compliance, and lowers process emissions, contributing to reduced Scope 1 and 2 CO₂ impact.
The result is a cleaner, safer, and more productive glass-forming process with less intervention, greater consistency, and longer-lasting tooling.
Glass Industry Challenges – How ThermaSiC Responds
Swabbing causing contamination, discoloration, production loss, emissions
Excellent non-stick performance against molten glass reducing adhesion, residue build-up, and eliminating swabbing needs.
Surface defects, unstable forming conditions, and shortened tooling campaign life
Stable low-wetting ceramic surface maintaining cleaner process conditions and more consistent gob handling over extended production cycles.
Thermal degradation and limited durability of conventional coating systems
High-temperature ceramic coating platform with service temperatures up to 1400°C eliminating softening, binder degradation, and thermal ceiling limitations.
Frequent cleaning interventions and downtime in hot-end operations
Reduced molten glass adhesion minimizing forced cleaning cycles, maintenance interventions, and operational interruptions. Improved health and safety for operators.
High wear on plungers, tongs, and glass-contact tooling
Excellent thermal stability and wear resistance, extending service lifetime of critical hot components.
High operating costs driven by scrap, downtime, and tooling replacement
Improved process cleanliness, longer component lifetime, and lower maintenance demand supporting measurable TCO improvement.
Increasing pressure for cleaner and more sustainable production processes
Heavy-metal-free ceramic coating platform enabling cleaner, more durable, and future-ready glass manufacturing operations.
Spray Shop
We see spray shops as innovation partners – advancing surface engineering through application expertise, industrial creativity, and collaborative development. This approach, driven by testing and partnership, is what we define as Open Surface.
Thermal spray shops have long been defined by engineering ingenuity and entrepreneurial problem-solving – from specialized operations to global service providers supporting production, aftermarket, and maintenance ecosystems. Today, rising performance demands, sustainability expectations, raw material volatility, and regulatory pressure are accelerating the shift beyond conventional carbide coatings.
Read more
ThermaSiC is developed with this industrial adaptability in mind. The advanced coating is fully compatible with established HVOF and APS processes, enabling seamless integration without changes to equipment or workflows.
As traditional carbide systems face cost inflation, supply uncertainty, and increasing scrutiny around critical raw materials, ThermaSiC offers a stable alternative. Its predictable cost structure enables greater pricing transparency, improved planning reliability, and reduced exposure to raw material volatility – supporting business continuity. This extends beyond procurement. As OEMs and end users seek next-generation coating solutions, spray shops can expand their offering and differentiate through enhanced wear resistance, non-stick performance, corrosion protection, high-temperature stability, and sustainability – beyond conventional carbide capabilities.
With increasing pressure on maintenance, downtime, and component lifetime, spray shops are well positioned to convert these challenges into high-value solutions and new aftermarket opportunities.
Catalytic strategic collaboration
The full application potential of ThermaSiC continues to evolve.
While key industrial use cases are already defined, its material behavior and process flexibility reveal opportunities beyond what can be developed in isolation. Collaboration is therefore not optional – it is central to how the technology advances, matures, and scales across industries.
Seram Coatings works closely with industrial partners, spray shops, universities, and research institutions to understand performance across different substrates, operating environments, and process conditions. The focus extends beyond validation to identifying where ThermaSiC delivers measurable technical, operational, and commercial value.
Read more
Dedicated R&D capabilities and continuous in-house testing and innovation enable new applications to be evaluated under controlled, repeatable conditions – reducing uncertainty and accelerating the path from concept to industrial deployment. Early-stage feasibility studies, sample spray coatings in our inhouse spray booth, and structured trials provide a practical framework for application-driven development.
For partners, this creates a clear pathway to explore new coating solutions on a robust technical foundation – combining material science, industrial expertise, and engineering pragmatism to address challenges where conventional technologies are reaching their limits.
Current projects
ESA – The Sky Is Not the Limit
Since 2022, Seram Coatings has collaborated with the European Space Agency (ESA) through the DuReCo program to explore and qualify ThermaSiC for aerospace and space applications.
The work began with feasibility studies on coating space-grade aluminum and titanium alloys, followed by testing under representative conditions, including simulated Martian dust exposure and cryogenic thermal shock.
The current phase expands qualification across key performance areas such as thermal cycling, high-temperature stability, wear and erosion resistance, coating adhesion, and tribological behavior—focusing on how advanced coatings interact with lightweight structural materials.
A central objective is to enable coated aluminum and titanium components that combine significant weight reduction with enhanced durability and environmental resistance. Target applications include thermal protection systems, dust-resistant surfaces, wear-critical mechanisms, sealing interfaces, and moving components operating under vacuum or limited lubrication.
The program progresses from performance mapping under representative environments to application-specific demonstrators validated under realistic conditions.
By combining Seram’s coating technology with ESA’s application expertise, the collaboration aims to enable lighter, more durable, and more reliable spacecraft and exploration systems.
Seram Coatings will present the project results at the International Symposium on Materials in the Space Environment in October.
OHB – Engineering for extreme environments in space
As part of the European Space Agency (ESA) DuReCo program, Seram Coatings is collaborating with OHB, one of Europe’s leading aerospace and satellite system providers, to assess the performance of ThermaSiC® in demanding space environments.
The partnership combines OHB’s space heritage with Seram’s expertise in advanced ceramic coatings to identify high-value applications where ThermaSiC® can outperform existing material solutions.
The program targets key use cases across extreme temperature environments, thermal protection systems, wear-resistant components exposed to abrasive particles, sealing surfaces for moving mechanisms, and tribological applications requiring low friction and minimal lubrication.
Through representative testing and analysis, the collaboration aims to build a detailed understanding of how silicon carbide-based coatings can enhance the performance and reliability of future spacecraft and satellite systems.
The long-term objective is to qualify ThermaSiC for aerospace applications where thermal stability, wear resistance, and durability are mission-critical.
Knorr-Bremse – Reimagining lightweight railway brake discs
Together with Knorr-Bremse, one of the world’s leading railway braking technology companies, Seram Coatings is exploring a next-generation brake disc concept for regional train applications, combining advanced surface engineering with lightweight substrate design.
The collaboration extends beyond coating validation. The project investigates the complete interaction between substrate material, surface treatment, and coating system to develop brake discs capable of delivering substantial weight reductions compared to conventional steel-based solutions. Such reductions have the potential to lower energy consumption, increase operational efficiency, and contribute to reduced lifecycle emissions across rail fleets.
A key focus is the evaluation of aluminum-based brake disc architectures as an alternative to traditional cast steel or particle-reinforced composite designs. In addition to significant weight-saving potential, alternative substrate concepts may offer improved recyclability and material recovery at end-of-life, supporting future circular economy objectives within the railway sector.
Ongoing development includes optimization of surface preparation methods to enhance coating adhesion and durability, alongside testing under thermal and mechanical loads representative of real-world braking conditions. Early results have demonstrated exceptional thermal shock resistance, with coated aluminum components showing no signs of cracking following rapid cooling from temperatures up to 400°C.
The long-term objective is to establish a new generation of lightweight, durable, and more sustainable brake disc systems for regional rail transport – combining reduced mass, extended service life, and improved recyclability without compromising safety or performance.
Research Council of Norway – Advanced sealing solutions
A Norwegian provider of downhole testing services faced recurring downtime caused by wear and leakage in a critical sealing system. Working together with Seal Engineering AS, ThermaSiC was identified as a potential alternative based on previous research demonstrating exceptional friction and wear performance against polymer sealing materials.
Following implementation, the coated sealing component has operated for more than five months without leakage or replacement, maintaining performance under demanding conditions and pressures of up to 70 bar.
The project demonstrates how collaboration between industry, engineering specialists, and research partners can translate advanced material science into measurable operational improvements – extending service life, reducing maintenance, and increasing equipment uptime.
