WICOATEC®: Low-Temperature CVD Technology for Efficient, Eco-Friendly Metal Coating
Summary:
Wieland Wicoatec’s WICOATEC® tech coats complex metal parts at 350°C, cutting chemicals by 95%, energy by 90%, and extending product lifespans.
Main description:
Wieland Wicoatec GmbH is a young, innovative company and part of the Wieland Group, one of the world’s leading producers of semi-finished copper and copper alloy products. Based in Vöhringen (Bavaria), the company specializes in advanced CVD (Chemical Vapor Deposition) coatings for complex metal components.
The project aimed to overcome a major barrier in applying CVD coatings to metals like aluminum and copper: conventional CVD processes require very high temperatures (typically >900°C), which are unsuitable for such materials. Existing alternatives, such as sol-gel coatings, were either not precise enough for complex geometries or resulted in high material and energy use. Moreover, coated products like heat exchangers often lasted only around six months, requiring frequent replacements and generating significant upstream material and environmental costs.
Wieland Wicoatec developed WICOATEC®, a low-temperature CVD process operating at ~350°C, allowing ultra-thin oxide-ceramic coatings on aluminum and copper parts—including complex internal geometries. The innovation lies in several key elements:
- Switching from thermal decomposition to acid-catalyzed hydrolysis of organosilane precursors
- Transitioning from a single-pass to a multi-pass chemical circulation system, extending the use of coating agents
- Implementing advanced process engineering, including lateral airflows, low-impulse outlets, and heated reactor walls to prevent unwanted condensation
These upgrades enabled high coating quality at lower resource consumption, significantly improving product durability and process efficiency. For example, heat exchangers coated with WICOATEC® now achieve longer operational lifetimes, reducing replacement frequency and preserving raw materials upstream.
Resources needed:
Technical:
- Custom-built CVD reactor system with gas recirculation and temperature control
- Innovative chemical dosing and flow control units
- Upgraded thermal and air management technologies
Financial:
- Substantial R&D investment in coating process and system development
- Supported by Germany’s Environmental Innovation Program
Environmental benefits:
Compared to conventional high-temperature CVD for coating 3,600 tons of aluminum components annually:
- 95% less silane used
- 95% less acetic acid used
- 99% aluminum material savings
- 90% reduction in electricity consumption
- 80% less natural gas usage
- ~2,000 tons CO₂-equivalent savings annually
Economic benefits:
- Significantly reduced material and energy costs due to lower chemical and utility consumption
- Extended product lifespan lowers maintenance and replacement costs for end users
- Potential for new revenue streams and market expansion in energy, heating, and machinery sectors
