This title appears in the Scientific Report : 2019 

Entwicklung von thermischen Spritzprozessen für fortschrittliche Schutz- und Funktionsschichten
Mauer, Georg (Corresponding author)
Werkstoffsynthese und Herstellungsverfahren; IEK-1
Jülich Forschungszentrum Jülich GmbH Zentralbibliothek, Verlag 2019
vi, 57
Habilitationsschrift, Univ. Dortmund, 2018
Habil / Postdoctoral Thesis (Non-german Habil)
Methods and Concepts for Material Development
Schriften des Forschungszentrums Jülich Reihe Energie & Umwelt / Energy & Environment 455
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This postdoctoral thesis draws on manuscripts published as first or co-author in peer-reviewedscientific journals and demonstrates their common theme. Based on examples of advanced protectiveand functional coatings, the specific, systematic development of thermal spray processesis described. This refers to the design of processes as well as to the development of new processes.Special importance is attached to the application of process diagnostics.The work was performed at Forschungszentrum Jülich, Institute of Energy and Climate Research,IEK-1: Materials Synthesis and Processing. First of all, the thermal spray processes available atthe institute which were applied in this work are briefly described. To achieve a better understandingof thermal spraying, the use of process diagnostics is indispensable. The purpose of thediagnostics described in the thesis is the characterization of the hot gas jet, the determinationof particle properties, and the characterization of the compounds of coatings and substrates.The first examples of applications given in this thesis are thermal barrier coatings for modern,highly loaded gas turbines to improve their lifetime or efficiency. Further examples are ceramicgas separation membranes for advanced fossil power plants as well as for other energyintensiveprocesses in the steel, glass, and cement industries. Moreover, different functionalcoatings for solid oxide fuel cells, photo-catalytically active coatings, and coatings for wear protectionthen follow.The given examples feature some baselines which suggest that the systematic development ofthermal spray processes should be regarded as a three-step approach comprising method →model → concept. Hence, the relations between process variables and coating properties whichare found by the methods described can lead to the development of physical models describingthe functional interdependencies between process parameters, on the one hand, and coatingresults, on the other hand. From this, concepts can be derived to realize particular coating properties.In performing this research work, the need for systematic development approaches becameclear, especially in the context of materials exhibiting particular processing difficulties such asdecomposition and inhomogeneous evaporation. In cases where solutions were found, the applicationof process diagnostics always played an important role