The Environmental and Economic Impact of Industrial Coatings
- December 4, 2024
Introduction
Sustainability and cost-efficiency are critical for the success in manufacturing and engineering sectors in today’s industrial landscape. The progress of advanced coating technologies has lately driven innovation in relative industries, as they strive for enhanced operational efficiency and minimum environmental impact (Challener ,2018), (Suárez-Vega et al., 2024). CoBRAIN project aims to improve the properties of thermal spray coatings by increasing their durability, and at the same time, minimise environmental and economic impact. Long-lasting coatings that withstand wear, corrosion, and tough conditions help industries reduce maintenance costs while significantly minimising waste and resource consumption.

The Role of Coatings in Industrial Sustainability
In industries such as aerospace, automotive, and energy, important parts frequently experience severe conditions leading to quick deterioration, erosion, and damage. Regular replacement or repair of these parts not only increase operational expenses but also produces a substantial amount of waste, depleting resources and energy. Nowadays coatings in these industries offer either limited protection, either containing critical materials leading to frequent reapplication or premature component replacement (Zhuk, 2019).


Industrial coatings with superior properties and advanced materials could truly be a game changer! By increasing the duration of parts, they will greatly decrease the necessity for repairs and replacements, ultimately cutting down on the manufacturing energy and material consumption. The main goal of the CoBRAIN project is to offer solutions towards the development of supreme quality and sustainable coatings utilising thermal spray techniques (HVOF, HVAF & CGS), with innovative materials. These coatings will present the required properties per case, mainly towards their resistance to wear and corrosion, enabling industries to sustain high productivity while reducing their environmental footprint.
Types of Advanced Coatings and Their Applications
Various advanced coating materials, including High Entropy Hardmetals (HEHs), ceramic-metal composites (Cermets), and polymer-based coatings, are essential for safeguarding industrial components against wear, corrosion, and harsh environmental conditions. In industries such as energy, automotive, and aerospace, one of the methods applied to create coatings is thermal spray like High-Velocity Oxygen Fuel (HVOF), High-Velocity Air Fuel (HVAF) and Cold Gas Spraying (CGS) offering improved toughness and protection in harsh conditions. HEHs not only applied to replace critical materials but also provide great protection against corrosion and wear, making them perfect for high-stress uses in these sectors. As explored in more depth in one of our prior blog post about HEHs, these alloys show very good mechanical strength and thermal stability, making them crucial for industries that need high-performance coatings. CoBRAIN utilising (Artificial Intelligence) AI-driven models to offer customised solutions for specific industrial requirements, guaranteeing that each use receives optimal durability and minimal environmental impact.


Environmental Impact and Circular Economy
High quality coatings offer substantial economic and environmental advantages in multiple industries (Bendikiene et al., 2019). High Entropy Hardmetals (HEHs) developed in the context of CoBRAIN project can be applied in many manufacturing industries to protect through coating numerous components of critical materials such as wind turbines, photovoltaics, batteries, vehicles (Mulvaney et al., 2019, Cherrington et. al., 2021) towards the expansion of their lifetime, reduction of maintenance downtime and decrement of component failures. By reducing discarded materials and damaged parts, waste disposal costs are lowered. Additionally, delaying costly replacements and minimising both initial and ongoing expenses lead to a significant reduction in overall costs. Aligned with the circular economy’s goal to extend product lifespans, these durable coatings enhance resource efficiency by reducing the need for new raw materials and minimising industrial waste. CoBRAIN combine AI and computational modeling to enhance coatings in industrial components for particular end – uses, guaranteeing high durability while minimising environmental effects. These advanced coatings also assist industries in achieving EU sustainability targets by lowering energy consumption during manufacturing and maintenance, thereby reducing CO2 emissions, energy use, and raw material usage.
AI and the Future of Durable Coatings
Leveraging AI to enhance coatings is a key feature of the CoBRAIN initiative. By integrating computational and experimental datasets, AI can predict material behavior under various environmental conditions and over extended usage periods. This enables the development of coatings that are not only exceptionally durable but also tailored to specific applications. Incorporating AI into materials science accelerates innovation cycles and fosters environmentally sustainable solutions, offering industries a pathway to balance performance with economic and environmental responsibility (Verma, et. al., 2023).

Conclusions
Developing innovative and sustainable industrial coatings, with enhanced properties is not only a technological advancement, but also a transition to a greener and efficient future for European industries. Advanced coatings assist industries to reduce their environmental footprint and improve their financial performance, mainly by minimising waste, decreasing material and energy usage, and prolonging the lifespan of crucial components. CoBRAIN project is a key component to achieve a greener future through the progress of industrial coating.
References
Challener C., Assessed date (September 2024). An update on sustainability in the coatings industry. CoatingsTech Magazine, 2018, https://www.paint.org/coatingstech-magazine/articles/an-update-on-sustainability-in-the-coatings-industry/
Suárez-Vega A., et. al., Exploring Sustainable Coating Solutions for Applications in Highly Corrosive Environments, Coatings, 2024.
Zhuk Y., Assessed date (September 2024). Improving component life in abrasive, corrosive aerospace environments, Aerospace Manufacturing and Design, 2019, https://www.aerospacemanufacturinganddesign.com/article/improving-component-life-in-abrasive-corrosive-aerospace-environments/
Bendikiene, R., et. al., Circular economy practice: From industrial metal waste to production of high wear resistant coatings, Journal of Cleaner Production, 2019.
Mulvaney, D., et. al., Progress towards a circular economy in materials to decarbonize electricity and mobility, Renewable and Sustainable Energy Reviews, 2021.
Cherrington, R., et. al., Exploring the circular economy through coatings in transport, Sustainable Production and Consumption, 2022.
Verma, J., et. al., Digital advancements in smart materials design and multifunctional coating manufacturing, Physics Open, 2023.