Materials for tomorrow Enhanced performance through advanced materials, surface engineering and polymer processing
02 GROUP OVERVIEW Attractive markets Every day, we are getting smarter in how we use resources. We demand that the objects that surround us, the cars we drive, the airplanes we ﬂy, even the clothes we wear, perform better and help us achieve more with less. What makes this possible are new and better materials, and new ways to shape them and give them purpose. Unique competences This is what Oerlikon does. We engineer and process materials and surfaces to give products improved and more desirable functions. We help cars and airplanes use less fuel, make tools last longer, and improve the manufacture of textiles. Our technologies enable manufacturers do things they simply could not do before and advance industrial innovation. Forward-looking strategy Oerlikon is a market leader in advanced materials, surface engineering and polymer processing. Our solutions encompass materials, coating equipment, coating services, and the engineering of entire plants. We build our busi- ness on unique technology competences, the widest global reach and trusted customer relations in highly demanding industries such as aerospace, automotive, energy, tooling and textiles. Every day, we develop on new materials, new surface technologies, new applications, components and textile manufacturing solutions to empower our customers to create and innovate better products. Markets we serve: Aerospace Automotive Energy Tooling industry General industries Manmade ﬁbers
PORTFOLIO 03 More proﬁtable More efﬁcient More sustainable More durable More productive Oerlikon Balzers is one of the world’s leading suppliers of surface technologies that signiﬁcantly improve the performance and durability of precision components and tools for the metal- and plastics-processing industries. It offers leading thin ﬁlm and nitriding coating expertise to more than 30 000 customers throughout all industries. Oerlikon Metco is a market leader in advanced materials, thick-layer surface technologies and turbine component solutions. It is one of the largest players in thermal spray materials and equipment with a ﬁrmly anchored position in the aerospace, power generation, automotive and industrial markets. Oerlikon Barmag is the world market leader in the development and production of spinning and texturing systems and equipment for manmade ﬁbers such as polyester, nylon and polypropylene. Oerlikon Barmag’s engineering services include Industry 4.0 solutions from the monomers all the way through to textured yarns and far beyond. Oerlikon Neumag is the worldwide market and technology leader for complete plants for the production of BCF car- pet yarns and synthetic staple ﬁbers. Furthermore, Oerlikon is also a leading solu- tion provider of a wide range of nonwoven technologies — with spunbond, meltblown and airlaid solutions, Oerlikon covers the technical and disposable nonwoven markets. Additive Manufacturing Oerlikon is a service provider of customized, industrial Additive Man- ufacturing solutions. It helps customers reduce product devel- opment times and production costs, shorten their supply chains, and increase the reliability, perfor- mance and sustainabil- ity of their manufactured products. Oerlikon partners throughout the entire Additive Manu- facturing value chain, or provides focused support to solve speciﬁc customer challenges in research and develop- ment, design, testing or engineering.
04 GROUP OVERVIEW Maximum protection EBC (Environmental Barrier Coatings) for turbine components manufactured from SiC-based CMCs (Ceramic Matrix Composites) ensure excellent thermal expansion and provide protection against vapor and other environmental attacks. This, in turn, maximizes the performance, reliability and durability of gas turbines. Turbine components such as airfoils, honeycomb seals and compressor vane assemblies ensure enhanced sealing and cooling of the turbine and improve engine efﬁciency. Coatings of pump and valve compo- nents in fuel and hydraulic systems reduce friction, protect against wear and increase component lifetime.
INDUSTRY: AEROSPACE 05 Saving the global aerospace industry millions of liters of fuel Every major aero engine manufacturer trusts Oerlikon technologies to boost performance, improve safety and fuel efﬁciency, and control emissions 5 % Thermal spray abradable coatings applied as clearance control solutions increase engine safety and boost efﬁciency by up to 5 %. TBCs (Thermal Barrier Coatings) pro- vide outstanding thermal protection for turbine engines and enable higher combustion temperatures permitting better fuel and engine efﬁciency. Coatings protect compressor blades against erosion and corrosion resulting in improved fuel efﬁciency and part durability.
06 GROUP OVERVIEW A coating that would work inside a live volcano … The interior of a jet engine can exceed 2000 °C — hotter than molten lava. To protect the engine’s turbine blades in such extreme operating tempera- tures, we developed a special thermal barrier coating. The coating is up to 250 µm thick and en- sures a longer life cycle, improved performance and increased safety. … making turbines more effective Our materials, coatings and turbine components increase the efﬁciency of the aero engine and protect a wide range of operational-critical parts, including clearance control systems, air seal components, compressor blades, vanes, impellers and IBRs (Integrally Bladed Rotors). By preventing problems caused by fretting, abrasion, particle erosion and other surface mechanisms, the coatings maximize turbine efﬁciency, optimize design point performance and improve thermal efﬁciency. Aerospace coating applications Fan blades Engine mount parts Compressor blades, vanes and seals Hydraulic systems and fuel pumps Turbine blades and seals Combustion chambers Actuators Airframe parts Rotor path linings Engine pylons Landing gears Tools for engine/airframe processing Tools for structure development Cockpit instruments
INDUSTRY: AEROSPACE 07 Making aerospace safer, more powerful and more efﬁcient Aerospace is one of the fastest-growing markets worldwide. In the last ﬁve years, passenger volume increased by a third — far faster than the International Air Transport Association (IATA) estimate. Today, 3.8 billion passengers ﬂy each year. That’s the equivalent of over half the earth’s population. And still, demand accelerates. In response, aerospace companies are developing next-generation airplanes. At the same time, they must increase efﬁciency and sustainability. To successfully address both challenges, some compo- nents — the jet engine, for example — need to change. They must become both lighter and more resilient to higher operating temperatures, fretting, sliding wear and corro- sion. Engines and many other critical components have to be developed further in order to reduce fuel consump- tion, and CO2, NO X and CH4 emissions. But manufacturers cannot achieve these goals alone. Oerlikon provides signiﬁcant added value with vital expertise in advanced materials and process technologies. We create new materials and coatings to improve performance across the aerospace industry. Additionally, we develop new textiles to ensure passenger safety. Many aircraft are already beneﬁtting. For example, our coatings protect turbine components and combustors from extreme temper- atures to achieve class-leading gains in operating efﬁciency. As a result, all next-generation aircraft engines make extensive use of these coatings. Compressor and turbine Engine hot section Landing gear Aircraft interior Increased safety and efﬁ- ciency with fewer emissions Abradable coatings are used in engines to seal the gas path and improve performance and efﬁciency of aero engines. They are a key component in engine operation safety and allow engines to operate using less fuel (1 % to 3 % efﬁciency gain) and as a result have a positive environmental beneﬁt of reduced CO2 generation and NOx emissions. Oerlikon is the leader in abradable coatings. Efﬁciency and lifetime increase at higher temperatures Thermal barrier coatings, including environmental barrier coatings and those resistant to CMAS, are used in the hot sections of engines (combustor and turbine sections) to allow the engine components to operate at higher temperatures, resulting in improved efﬁciency. These coatings protect the underlying materials from tem- peratures that the substrates could not otherwise tolerate. Safe and reliable landing gears In the past, landing gears were hard chromium plated. Now, they can be coated with Oerlikon’s HVOF (High Velocity Oxygen Fuel) thermal spray technology. Why? Because the HVOF coatings exceed the perfor- mance of hard chromium plat- ing and meet the demanding requirements of the new generation of aircraft while replacing the noxious hard chromium process. Attractive protection and color coding In every aircraft, a pilot needs to see the different screens in the cockpit in order to determine the altitude, speed and attitude. Pilots are under constant pressure to ﬂy and land safely. Therefore, cabin ﬁxtures should not be reﬂective or the pilot may miss vital data. That’s why Oerlikon developed the BAL- TONE coating solutions.
08 GROUP OVERVIEW Increased engine performance 2 % to 4 % fuel saving Coatings applied to cylinder bores result in low friction, low oil and fuel consumption, reduced wear and increased corrosion resistance. Coated piston pins and injector nozzles in turbochargers withstand the higher pressure and tempera- tures needed to improve performance while curbing emissions. Improved resistance Coatings for steering and suspension components guarantee increased surface hardness, wear and corrosion protection, and a longer lifespan.
INDUSTRY: AUTOMOTIVE 09 Advancing productivity, sustainability and proﬁtability in the automotive industry More than half of the world’s top ten car manufacturers use Oerlikon technologies to increase component lifetime and reduce fuel consumption Environmentally friendly ePD coated (embedded PVD) parts are fully recyclable and employ an environmentally friendly metallization technique. No harmful agents such as hexavalent chromium or other heavy metals are used in the process. It enables plastic parts to be coated with metallic effects in automobiles as important interior and exterior design elements. 40 % Reduced emissions Up to 40 % friction reduction through wear and corrosion preventive surface solutions. Brake disc coatings protect against wear and corrosion, reduce brake dust emissions and increase disc lifetime.
10 GROUP OVERVIEW Lighter, slicker, more effective We produce advanced coatings for over 100 car parts that reduce corrosion, friction and wear. The resulting fuel efﬁciency and improved durability of light metals means manufacturers can build smaller engines. When manufacturers adopt a comprehensive approach to component coating, they can cut fuel consumption by 2 % to 4 %, reduce oil consumption by 30 %, and cut engine block weight by 12 %. 14 15 16 12 13 11 Over 100 components per car In today’s cars, over 100 components are coated and up to 30 kg of textiles are used. 10 1 3 4 2 5 7 6 9 8 Typical applications in the automotive sector 1 Production tools 2 Engines 3 Valves 4 Fuel injectors 5 Exhaust systems 6 Transmissions 7 Gears 8 Suspension 9 ESP/brake system 10 Turbochargers 11 Decorative elements 12 Safety belts 13 Interior elements 14 Moldings 15 Exterior decoration 16 Tires
INDUSTRY: AUTOMOTIVE 11 Driving automotive improvements by reducing weight, fuel and emissions The automotive industry is on the rise. “In 2015, 1.0 billion cars were on the road. Driven by the increasing global demand for mobility, that number will grow to over 2.4 billion by 2050.”* Vehicle manufacturers are faced with growing demands from regulators, customers and investors to increase manu- facturing productivity, boost vehicle operating efﬁciency and reduce their environmental impact. To reduce fuel con- sumption, cars need to lose weight and gain engine efﬁciency. Yet safety concerns call for increased robustness and more onboard technology. Vehicle manufacturers are looking for new and innovative ways to address these challenges. New and advanced materials, improved performance of components or new ways of manufacturing components are all part of the solution. Oerlikon’s innovative powertrain concepts reduce energy loss from the engine to the wheels. Our specialized coatings improve wear resistance and the life of key components. Advanced materials make designs more compact, reduce weight or friction losses in the engine, and make new design solutions possible. And our manmade ﬁber solutions improve passenger safety and comfort — from airbags and safety belts to seats and tires. Improved engine reliability and performance Smoother-shifting transmissions Innovative, chrome-look design parts Further improving passenger safety Injectors, valves, oil pumps, exhaust systems, cooling sys- tems, turbochargers: every part of an engine has to perform perfectly and reliably. Oerlikon coating technologies improve the performance and durabil- ity of engine components. The coatings signiﬁcantly reduce friction and wear resulting in improved fuel and oil efﬁciency, lower emissions and longer component lifespan. From cars to trucks to construc- tion vehicles, Oerlikon offers comprehensive synchronizer and friction reduction technolo- gies for modern transmission systems. Beneﬁts include increased performance, excel- lent oil compatibility, enhanced comfort, extended life cycle, lower weight, improved wear resistance and reduced costs. Now, door handles, mirrors, push buttons, switch cov- ers, gear shifters, frames and many more parts can look like chrome without the unsustain- able chromium plating process. Oerlikon’s PVD and ePD tech- nologies offer environmentally friendly, chrome-look plastic metallization. Manufactur- ers can offer their customers the aesthetics they want and please regulators and nature at the same time. Brake discs, safety belts, airbags and tires are all key to vehicle and passenger safety. The reliability and quality of the materials used are essential if every single part has to work to perfection every time. Oerlikon technologies such as brake disc coatings and manmade ﬁber solutions equip manufac- turers with technologies that further increase vehicle safety. * International Transportation Forum (ITF)
12 GROUP OVERVIEW Corrosion and erosion protective coatings applied to hydropower turbine components extend service life, increase turbine efﬁciency and decrease maintenance costs. Coatings protect gas turbine components from oxidation, hot gas corrosion, erosion and wear. Combined with specialized turbine components, they maximize operational efﬁciency and reliability with less environmental impact. Surface solutions increase wear resistance, improve component per- formance and extend the time between maintenance cycles of gears, roller bearings, hydraulics and structural parts required for reliable wind power.
INDUSTRY: ENERGY 13 Empowering and electrifying the way we generate energy The world’s largest energy turbine producers improve the efﬁciency and cut the environmental impact of their products with Oerlikon technologies < CO2 Tailored materials and coatings protect ball valves used in the oil and gas industry from galling, abrasion and erosion resulting in smooth, reliable operation and preventing unintentional valve backﬂow or leakage. Abradable sealing coatings for steam turbines result in increased power output and efﬁciency, while reducing fuel consumption which lowers CO2 emissions. Coatings protect centrifugal injection pumps used for hydraulic applications from abrasion, erosion and corrosion and extend the pump time to failure by a factor of over three.
14 GROUP OVERVIEW Oil and gas Hydro turbines Some of the harshest stresses and strains are found inthe world of oil and gas exploration: abrasive wear, erosion, corrosion, fatigue, high ﬂuid pressure, vibrations, impact loads, extreme torque and many more. To protect vital components, Oerlikon developed tai- lored materials combined with thin ﬁlm and thick-layer surface solutions. These advanced coatings extend the lifetime of downhole tools, pump parts, valves, drill bits, stabilizers, drill collars and mud rotors by up to ten times and reduce malfunctions and downtime. Hydropower is the primary renewable energy source used to generate electricity. Corrosion and ero - sion cause efﬁciency losses that are worsened by the amount of entrained silt, sand and gravel in the water. Oerlikon materials and coating technologies for hydropower turbine components reduce material erosion by a factor of up to 50 and increase the service life of components three to ﬁve times compared to uncoated components. Gas and steam turbines Wind turbines Parts in the turbofan, compressor, combustor, turbine and exhaust section all beneﬁt from Oerlikon tech- nologies: everything from blades, vanes and shrouds to shafts, disks, bearings and nozzles. For example, PVD-coated compressor blades last twice as long as uncoated versions. Abradable coatings for clearance control increase efﬁciency by up to 5 %. Thermal barrier coatings protect against heat. And Oerlikon-manufac- tured turbine components enhance sealing and cooling. Wind power installations have to work in sun, rain, snow and wind. Those located offshore must also contend with salt, which poses a constant threat of corrosion. A standstill incurs enormous costs. So our dedicated materials and surface solutions guard against wear, corrosion and fatigue. One example is transmission gears, which are subjected to up to 144 million revolutions of the rotor shaft, or 15 billion revolutions of the generator shaft, during their service life.
INDUSTRY: ENERGY 15 Increasing power plant productivity to cover the ever-rising demand for energy Energy. Every day you use it, consciously or uncon- sciously. When you watch TV. When you work on your computer. When you turn on a light. When you charge your phone. By 2030, global primary energy consump- tion is expected to rise by up to 40 %. Propelled by this growth, the energy sector will continue to expand. The spiralling demand for energy and the threat of climate change, combined with decreasing costs of renewable energy sources, are transforming the energy sector. Energy companies are racing to meet demand, but also to improve the efﬁciency of non-renewable technologies like oil and gas and to promote renewable energy technologies like solar and wind turbines. The industry needs new materials to achieve these goals. Oerlikon has the answers. For example, equipped and treated with our technologies, turbines last longer and perform more efﬁciently and reliably. Recently, our products improved the wear resistance of steam turbine compo- nents by a factor of 25. But we still have more to achieve. Collaborating with hundreds of researchers and universities around the world, we are working to create advanced solutions for a new energy future and opportunities to provide products with superior functionalities. Coatings and materials developed over the years can withstand exposure to extreme conditions and so promote safe, efﬁcient, economical work processes. Coatings have had such a great impact that they’ve become essential to preserving equipment, increasing energy efﬁciency, and ex- tending the useful life of materials used in industrial applications. Dr. Wolfgang Konrad Head of Oerlikon Metco Aero & Engergy Typical applications for the energy sector Gas and steam turbines Blades, vanes, combustion chambers, connecting studs, seal segments Hydro turbines Blades, vanes, sleeves, bear- ings, wheels, cranks, pins, needle spears, nozzle tips Wind turbines Planetary gear elements, roller bearings, ring gears, shafts, pylons, blades Oil and gas Drill collars, mud motor rotors, drill stabilizers, tricone bits, ball and gate valves, riser tensioners, mandrels
16 GROUP OVERVIEW 50× Coated punch and die tools to produce safety belt latches have an extended lifetime of up to 50 times longer and provide perceptibly better surface and cut quality than non- coated tools. Tools coated with Oerlikon technolo- gies operate at 30 % higher cutting speeds for the production of gears for gearboxes, resulting in shorter machining time. Tools, such as drills, can be reconditioned up to three times, lead- ing to a 50 % cost saving for new tool purchases.
INDUSTRY: TOOLING 17 Sharper, stronger and more durable tools The world’s most leading and respected tool manufacturers apply Oerlikon technologies to improve tool productivity and lifetime Chemical stability Coated tools allow more than 350 holes to be drilled with the same tool compared to only 60 holes with uncoated tools. This leads to higher efﬁciency in the production process. Chemical stability coatings protect cutting tools from corrosion by chemical/electromechanical reaction between a metal and a substance with which it comes into contact. Coated threaded cores for the production of bottle caps lead to trouble-free production and productivity gains of up to 20 %.
18 GROUP OVERVIEW Improving the performance from the smallest precision tools to largest tools for metal die casting Efﬁcient, reliable tools are at the core of all industrial production. And more are needed with every passing day. When vehicle manufacturers produce cars, aircraft manufacturers fabricate airplanes or construc- tion engineers build new energy systems, they all depend on manufacturing tools to perform effectively. In fact, tool performance is primarily responsible for the quality, cost and overall factory output of any product. For optimum performance and service life, modern machine tools need to withstand higher temperatures and pressures, as well as increased wear and friction. Coatings and heat treatments are among the most effec- tive ways to improve tool performance. This in turn leads to greater productivity and quality of metalworking and plastics processing. In close partnership with our toolmaking customers, we are developing the right solutions for every tool in the manufacturing process. The results are impressive: longer service life, lower manufacturing costs, higher production reliability, and enhanced corrosion and adhesion protection. Over 20 % increase in cutting performance Up to 30 % produc- tivity gain in plastics processing Tenfold extension of lifetime of forming tools 100 % performance with up to 70 % cost savings Cutting tools in particular must provide high precision, fast cutting rates, long lifetimes and low production costs. Whether turning, milling, drilling, ream- ing, threading or gear cutting, tools are exposed to extremely high temperatures. In plastics processing, such as injection molding and extrusion forming, tools play a key role for productivity and process reliability. In particular, the mold surface plays a crucial role. The better the tool quality, the greater the productivity and efﬁciency of the manufacturing process. When forming stainless steel, untreated tools quickly ap- proach their limits. In produc- tion, punching, stamping and forming, tools are exposed to extreme forces and subject to wear. Specialized coatings with low friction coefﬁcients and a low tendency to adhere facilitate the machining of difﬁcult materials such as aluminum, titanium and magnesium alloys, as well as high-strength steels. Coated forming tools provide excellent protection against corrosion and reduce friction and wear. Oerlikon, as the technology leader in hard coat- ings, provides the benchmark in plastic processing. Metal forming tools require long-lasting, high-quality, reliable and robust processes to ensure high productivity. Economic efﬁciency and preci- sion are key goals of all stamping processes. Its latest wear protection solu- tions push the performance of molds. The results are longer tool life, less scrap, improved part quality and lower produc- tion costs. Surface scoring, pickup, galling, burrs and other surface defects on the parts create rework or scrap and add to the cost. Oerlikon provides optimal protection solutions to minimize wear for punch- ing and forming tools that can save up to 86 % of the costs. Challenges in die casting pro- duction processes are tolerance and production cycle times. An essential factor for the success of metal die casting is the qual- ity of the mold surface. It must withstand high temperatures, erosion, oxidation and other harmful effects. An untreated mold can quickly fail, leading to high costs. To prevent this, Oerlikon developed exceptionally hard, extremely erosion- and wear- resistant coatings that prevent mold erosion, abrasion, melt- sticking and oxidation, as well as alloying and premature heat checking. The results are lower tool costs due to signiﬁcantly prolonged tool service life, increased productivity and production reliability.
INDUSTRY: TOOLING 19 Cutting • Drilling • Milling • Gear cutting • Broaching • Turning • Reaming • Threading Metal forming • Drawing and forming • Roll forming • Trimming operations • Hot forming • Fine blanking • Draw rings • Punches and die buttons • Cold and hot forging Plastic processing • Melt touching • Nonmelt touching Die casting • Molds • Cores • Inserts
20 GROUP OVERVIEW Raising product capabilities from hygiene and safety to performance and durability Companies from a broad range of industries employ Oerlikon surface technologies to offer superior products Coated medical components ensure biocompatibility of implants or pacemakers, increase the survival and success rates of surgical implant treatments and reduce infections. Coatings for antennas are applied to non- or poorly conductive materials to enhance electrical conductivity. Plasma-sprayed chromium oxide coatings on anilox rolls ensure successful laser engraving of the ink-metering cells and protect the anilox roll from the corrosive effects of the ink.
INDUSTRY: GENERAL INDUSTRIES 21 Coatings with very smooth as-sprayed ﬁnishes applied to corrugating rolls for the paper industry signiﬁcantly lower post-coat machining costs and extend the useful life of the roll. Coatings that prevent surface fatigue of roller bearings reduce mechanical stress, lead to an extend- ed life time and increase the durability of components. Implants and surgical ﬁxtures coated with titanium or hydroxyapatite ﬁt perfectly thanks to an improved porous structure that supports bone growth.
22 GROUP OVERVIEW Medical: biocompatible and antimicrobial Consumer goods: decorative and service life • Medical instruments • Knee or hip implants • Bone drills • Dental implants • Dental instruments • Bone saws • Watches • Washing machines • Consumer electronics • Pots and pans • Windows • Shavers • Sanitary ﬁttings • Automotive interiors/exteriors Food and packaging: hygiene and productivity Energineering: performance and durability • Food processing • Plastic ﬁlms and foils • Labeling • Bottles and liquid containers • Paper production • Chemical processing • Biofuels • Water and wastewater applications • Instrument panels • Air vents • Batteries • Semiconductors • Agricultural machinery • Construction equipment • Diesel locomotives • Printing presses
INDUSTRY: GENERAL INDUSTRIES 23 Empowering products to achieve better results Uncompromising quality, extreme cleanliness, regula- tory compliance and easy-to-clean components are just a few of the requirements in medicine and food processing. Away from the pressures of patient safety and food hygiene, manufacturers of household appli- ances, consumer electronics and sports equipment develop their products with components that are either crucial decorative elements or important for a better product service life. In engineering, performance and durability of the com- ponents are of key importance. This applies from simple mechanical applications to high-end semiconductor engineering. Oerlikon provides a wide range of precision and high- quality coatings with properties to protect or enhance the performance of components or entire processes. Our medical coatings help keep medical instruments clean or support postoperative healing, increasing patient quality of life. In consumer goods, coatings mean components can be smaller and lighter. Our decorative coatings deliver unbeaten wear resistance and designer ﬁnishes. In engineer- ing, they signiﬁcantly improve the performance and durability of parts. Consumer goods Medical Food and packaging Engineering From watches to lifestyle equip- ment, from vacuum cleaners to coffee machines — consumer goods need to be reliable, durable and attractive. Most household appliances, consum- er goods and sports equipment use metal or plastic parts. Fighting bacterial infections often begins before or during surgery. Coatings on medical devices provide treatment- critical functions and are a rapidly growing area. Coating these parts enhances and improves the performance and service life of modern consumer goods. It makes their production more efﬁcient and it ensures that they meet the highest industry standards and latest consumer tastes thanks to superb designer ﬁnishes. Such functionality can be achieved through coatings that are either extremely hard or decorative or both. Oerlikon’s range of medical coatings includes antimicrobial coatings to prevent infections, biocompatible coatings that support the integration of a metal implant into the bone and non-reﬂective coatings on surgical instruments that aid surgeons’ concentration. The coatings also include solutions that improve the quality and durability of medical devices, which often have to perform for many years inside the hu- man body. Hygiene, productivity and reli- ability are critical factors in food processing and packaging. Most importantly, food must never become contaminated in the processing environment. Machines and equipment must be easy to clean and have to withstand corrosive conditions caused by, for example, fruit acids or cleaning agents. Forming, ﬁlling and sealing food is often synchronized with packaging and labeling. These processes all demand innova- tive and high-performing engineering solutions. Coatings from Oerlikon help maintain hygiene, reduce wear, extend the service life and thereby signiﬁcantly improve the manu- facturing process. The results are safer processes and substantial cost savings. Engineering applications need to perform to the highest standards, day in, day out. Whether mobile phones, Wi-Fi equipment or highly sensitive semiconductors, they are all manufactured using the latest engineering technology. But mechanically engineered components often operate under extreme conditions such as high loads, rapid sliding speeds or poor lubrication. Coatings from Oerlikon minimize friction, wear and corrosion, and enhance the reliability, service life and performance of such components. And specialized, precisely tailored coatings for semiconductors production satisfy the stringent requirements of the industry.
24 GROUP OVERVIEW Customized metal additive manufacturing production solutions for a range of industries Major industrial companies partner with Oerlikon in 3D metal printing to build their next-generation components Aerospace Automotive Energy Typical aerospace applications are complex engine parts, structural components and replacement parts. Additive Manufacturing enables the production of such parts at lower weight and signiﬁcantly reduced costs. Additive Manufacturing allows our customers the design freedom to consolidate several parts into one to reduce weight and supplier count. Reducing weight allows car companies to meet new legislation targets for fuel efﬁciency. Additive Manufacturing enables the production of highly complex ﬂuid- ﬂow- and corrosion-resistant compo- nents from superalloys that can operate in demanding environments. Our customers beneﬁt from our ability to manufacture and coat these complex components.
INDUSTRY: ADDITIVE MANUFACTURING 25 Tooling General industries Medical The use of Additive Manufacturing to produce tools and tooling components reduces lead times and costs. Addition- ally it improves part functionality and provides design freedom to customize products. From prototype applications to on- demand parts, manufacture of small batches or mass customization, Additive Manufacturing allows com- panies from all industries to design products in a way that perfectly meet their needs. Since every patient is unique, Additive Manufacturing opens up new pos- sibilities for medical treatments as it allows rapid customization of medical devices such as implants, instruments and models very fast with high preci- sion, high quality and with the biggest positive impact on health.
26 GROUP OVERVIEW Cutting development times to build more complex and efﬁcient products From metal powder atomization to advanced compo- nent production and assembly, Oerlikon provides AM (Additive Manufacturing) services for industrial companies all over the world. We provide focused support to solve speciﬁc customer challenges in R&D, material supply, design/engineering, testing and manufacturing of their AM products. The result? Customers can reduce time to market, shorten their supply chains and increase the performance of their components. We are experts in atomized metal powders. We have extensive expertise in the engineering and manufacturing of industrial components. And we know the AM challenges and needs of our customers’ industries. Engineering and design Materials Additive production Post- processing Mastering functional design Choosing the right materials Knowing advanced manufacturing Enhancing surface functions Manufacturers create designs using CAD to make a 3D model of the product. To take full advantage of the design freedom AM offers, they need in-depth technical and domain-related knowledge, and expertise in materials, application design and the setting of process parameters. AM industrial components pri- marily require the use of metal powder with a high purity and very narrow distribution of granular size. A growing number of metals are being used for industrial AM applica- tions. The most common are aluminum, cobalt, stainless steel and titanium. Printing additively manu- factured products, layer by layer, by melting powder with a specialized, high-power laser requires corresponding capabilities: adequate printing equipment and know-how about building structures and programming process parameters. Additively manufactured components often require post-processing to achieve the desired surface functionalities, dimensional accuracy, ﬁnal mechanical characteristics and material properties. Oerlikon has industry-leading expertise in the design and engineering of industrial components and the related process chain. We support our global customers in their needs for AM R&D, design, testing and engineering. Oerlikon has over 80 years experience in developing and manufacturing materials for critical industrial applications. We offer a market-leading material portfolio serving processes such as thermal spray, laser cladding, brazing, weld hardfacing and more. It spans metals and alloys, wires, carbides, ceramics and abradables, including fully AM-certiﬁed materials. Oerlikon has long-standing and leading know-how in manufacturing high-perfor- mance industrial components. We are a leader in the design, development and engineering of aerospace and industrial gas turbine components. Oerlikon is the technology and market leader in surface engi- neering (coating) and offers the full range of post-processing applications. These range from hot isostatic pressing to heat treatment, machining, surface treatment and ﬁnal quality inspection, provided through an established global service network.
INDUSTRY: ADDITIVE MANUFACTURING 27 Optimized design and high complexity AM allows development of highly complex designs in new geometries and materials New business models Parts or entire products can be built on demand, which have enormous implications for the way manufacturers design, build and sell their goods Shorter innovation cycles Innovations are designed, developed and tested more rapidly, eliminating the need for expensive and time- consuming part tooling and prototype fabrication Faster time to market AM provides a fast track from concept to production, where complex objects can be manufactured in a single process step Perfect for mass customization Its ﬂexibility and customization at low unit costs make AM optimal for small pro- duction batches and mass customization of components and parts Performance enhancement Additively manufactured parts can be designed with new properties, features and materials to improve performance Elimination of production steps AM lowers the cost of manufacturing by reducing the outlay on high-value materials and shortens lead time Antenna bracket for Sentinel satellites — certiﬁed for use in outer space Project management, design optimization and testing by RUAG; advanced component production by citim (an Oerlikon company).
28 GROUP OVERVIEW Improved energy efﬁciency Reduction in energy consumption is becoming increasingly important for textile manufacturers. In the develop- ment of new components, machines and systems, Oerlikon is constantly optimizing the efﬁcient utilization of the energy consumed. Thanks to Oerlikon’s knowledge, it is possible to achieve energy savings of up to 50 %. Use of sustainable technologies and recyclable products Proﬁtable, sustainable growth for all stakeholders is the goal at Oerlikon. The company is thus making its contribution to securing the future. Performance, quality, sustainability and passion are the factors that enable Oerlikon to face the challenges of the future day by day. Compact machine design and efﬁcient use of space The inﬂuence of ergonomically designed components and machinery is often underestimated. In addition to rational considerations, ergonomic knowledge also forms the basis for space-saving machine designs with clearly structured and easy-to-grasp operating and control elements that embrace Industry 4.0 solutions.
INDUSTRY: MANMADE FIBERS 29 Serving the growing need for better functional ﬁbers and apparel The world’s largest textile manufacturers trust Oerlikon’s ﬁlament spinning, texturing, BCF carpet yarn, staple ﬁber and nonwoven machine solutions Low production costs and machine downtimes Optimally designed equipment sup- ports the ecological balance in many ways: labor costs and downtimes for maintenance are dramatically reduced, and consistent quality and efﬁcient production are ensured. Highly reliable processes Oerlikon engineers look back on decades of experience in the production of polyester, nylon and polypropylene. The tried-and-true technologies are used in nearly every manmade ﬁber production plant worldwide. With a conversion rate of more than 99 %, Oerlikon guaran- tees reliable processes for industrial production. High-quality output Each year, millions of tons of poly- ester, nylon and polypropylene are produced on tens of thousands of Oerlikon machines, which is why the quality and the characteristics of the razor-thin ﬁlaments and yarns must always be the same — if they are not, the ﬁnal fabric will eventually show the differences.
30 GROUP OVERVIEW Textiles and apparel Functional wear Transportation Filament yarns are largely used for textiles and apparel. Today, polyester, nylon and polypropylene yarns are the primary materials to manufacture cloth- ing. From the ﬁnest suits to heavy- duty applications, modern clothing is building on yarns and ﬁbers to perform. Yarns are the starting material for a wide range of fabrics — from fashion, sports and home textiles to specialty functions such as bulletproof vests and ﬁre protection gear. Aerospace textiles, automotive applications such as tires, safety belts and airbags, sails, and much more are manufactured using industrial yarns. Packaging Flooring and textile Medical and ﬁlters Polymer processing creates a large number of potential applications for the production, handling and packaging of food and goods. From bottling to insulation to foils that protect food from external effects, yarns are designed to perform speciﬁc functions. Textile ﬂooring applications, such as carpets and various home textiles in diverse shapes and colors, are manufactured with manmade ﬁbers. Those applications need a highly resistant material. And that is exactly what Oerlikon materials can provide. Yarns are also used for a wide range of ﬁlter applications. They provide speciﬁc functions such as absorbency, liquid repellency, resilience, stretch, softness, strength, ﬂame retardancy, washability, cushioning, thermal insulation, acoustic insulation, ﬁltration, microbial barrier and sterility. Infrastructure The applications are as diverse as they are speciﬁc: from ﬁbers for geotextiles to rooﬁng and monoﬁlament and tapes for agricultural applications such as baling twines, bulk goods sacks and windbreak netting. By consistently expanding the e-save philosophy in the Oerlikon manmade ﬁbers business since 2004, we are con- tinuously making a difference through high-quality, innovative industrial solu- tions. Oerlikon’s innovations are developed with the following four e-save aspects in mind: energy, economics, environment and ergonomics.
INDUSTRY: MANMADE FIBERS 31 High-performing yarns for every type of product The global need for textiles from markets such as clothing, electronics, food, functional wear, infra- structure and transportation is growing rapidly. Apparel, functional wear, carpets, automotive tires, safety belts, airbags, geotextiles for construction, ropes, conveyor belts, sails and ﬁlters to clean water and air all rely on ﬁbers. But natural ﬁbers use too many resources, for example water, for their production, or cannot offer the functionality needed. Industrial yarns are the solution — they form the basis for almost all technical textiles. Ever since manmade ﬁbers were created, the goal has been to give the smooth, synthetic ﬁlament a natural ﬁber- like character and speciﬁc functions such as elasticity and increased heat retention. Oerlikon is the world market leader for systems used in the manufacture of manmade ﬁbers. We offer technologies from melt to yarn for manu- facturing industrial yarns, ﬁbers and nonwovens. Oerlikon’s large-scale ﬁlament spinning and texturing are designed to manufacture and process polyester, polyamide and nylon, as well as high-tech production systems for carpet yarns, synthetic staple ﬁbers and nonwoven fabrics. From melt to yarn, ﬁbers and nonwovens — Oerlikon offers solutions along the entire value chain.
32 GROUP OVERVIEW Making a material difference in next generation’s industrial products No. 1 > 20 Widest-ranging portfolio of surface technologies, advanced materials, coating equipment and services. From melt to yarn — world market leader for systems used in the manufacture of manmade ﬁbers. Over 20 different surface proper- ties offered. 13 840 Number of employees. Comprehensive coating services in more than 140 dedicated customer centers in all major industrial regions of Europe, Australia, Asia and the Americas. Innovation: over 1 000 engineers are dedicated to the research and devel- opment of new technologies, applica- tions and solutions for our customers. > 95 More than 95 years of materials engineering and processing expertise. Standard and tailor-made solutions for various industries. Equipment and manufacturing sys- tems for seamless integration into our customers’ production systems. > 50 2 331 42 Partner of more than 50 institutes worldwide. Sales in CHF million. Number of R&D centers.
OERLIKON: SERVICES 33 Forward-thinking technologies We are a global, high-tech engineering group dedicated to share our unique competences and technologies to enhance the performance, productivity and durability of our customers’ products and solutions. Our solutions encompass materials, equipment and services including the engineering of entire plants. We continually expand our industry-leading portfolio with the latest technologies and solutions. Customers who already use our technologies have rapidly expanded their application range. We build on our leading, wide-ranging technology portfolio, the widest global reach and trusted customer relations in highly demanding industries such as aerospace, automotive, energy, tooling and textiles. We have a proven track record in innovation, quality and reliability. Our employees are committed professionals with an expert understanding of technology and industry-driven innovation. Surface solutions Advanced materials Materials processing Number one in surface solutions: We offer the most comprehensive portfolio of surface technologies. Together with our customers, we develop tailor-made solutions for various industries from coating of components to high-precision tools. Broad portfolio of advanced materials: We understand the properties of materials at the smallest scales and are a world-class materials manufacturer of powders and wires for coating applications and specialty markets. Customers can choose from our standard portfolio, but can also order customized materials and surface solutions for their speciﬁc applications. We provide hundreds of diverse products to choose from, including the broadest line of thermal spray coating materials and auxiliary products in the world. Unique component engineering expertise: We offer comprehensive know-how in the engineering and processing of materials and surfaces to design high-performance industrial components. We apply our strong complementary expertise in materials, software and pro- duction of high-performing components to offer AM-based advanced component manufacturing capabilities as an end-to-end AM process for the entire value chain. Our offering ranges from design, prototyping, individualized components and series to mass production and repair/service. Materials Coating services Equipment and systems Engineering We offer the widest range of advanced materials for surface solutions and Additive Manu- facturing production. In more than 140 dedicated customer centers, we offer coating services that are rigorously geared to customer needs — from pickup to clean- ing, regrinding, re-treatment, post-treatment to polishing. We provide highly productive and reliable systems for a wide range of requirements, includ- ing customer-speciﬁc on-site production lines. We offer engineering and design support for tools and components. We provide standardized and customized solutions developed in coop- eration with our customers.
34 GROUP OVERVIEW Serving our customers locally Production and R&D sites New sites in 2016 (incl. production) Other Oerlikon sites (incl. production) Partners (distributors, representatives)
OERLIKON: SERVICES 35 182 sites globally 38 in the Americas 60 in Asia 84 in Europe 177 sales and service sites 55 production and R&D sites Contact us www.oerlikon.com