Thermal High-Temperature Technologies

At a glance

The generation, supply, and storage of energy often involves high temperatures. Materials in solar power plants, for example, have to withstand temperatures of up to 1000 ºC, while gas turbines have to withstand temperatures of over 1250 ºC. Key components of these systems are also exposed to high levels of corrosion and erosion.

Jülich experts develop advanced coatings and structural materials with exceptional durability that can work reliably even under extreme conditions. This includes steels and other alloys as well as structural and functional ceramics – also as protective coating systems – which are produced using innovative manufacturing processes such as additive manufacturing and thermal spraying.

Challenges

Materials that are exposed to high temperatures or extreme temperature fluctuations are subject to enormous stress. This leads to thermal fatigue and wear. In aggressive environments, such as high water vapour pressure during the combustion of hydrogen or in heat transfer media such as molten salt, liquid metals, or ceramic particles, cracking, corrosion, and erosion occur. These factors weaken the material in the long term. Materials are therefore needed that can withstand all these challenges over a long period of time.

Solutions

The Jülich research groups conduct basic research in order to gain a better understanding of physical and chemical processes at the microscopic level. They combine computer simulations with analytical methods, automation, and machine learning to develop new models and optimize materials and manufacturing processes. They investigate microstructures to better understand the mechanical properties of materials. This helps to predict and minimize material failure.

In addition, Jülich scientists are developing ceramic composites, high-temperature-resistant metals and alloys, and innovative coating technologies that are also widely used in industry.

In the field of gas turbines, Jülich researchers are focused on the development of materials and advanced coatings that are particularly temperature-resistant and can withstand cyclical temperature fluctuations and the associated mechanical stresses. The Jülich Thermal Spray Center (JTSC) offers a comprehensive range of thermal spray processes that are used for numerous industrial applications, including aircraft engines, stationary gas turbines, fuel cells, and solar power plants.

The Jülich experts are developing and testing key components for concentrating solar power, such as receivers and heat exchangers. In the field of thermal energy storage, they are working on structural materials with improved corrosion resistance, supplementing these research approaches with a thermochemical database for high-temperature heat fluids.