Alleima adopts thermal spraying technology to support green transition
May 8, 2025
Alleima, headquartered in Sandviken, Sweden, reports it has invested in new thermal spray technology. The company aims to develop new products in the field of sustainable energy, where, for example, it can be used in the production of electrolysers used for green hydrogen production. The company said it is in dialogue with several customers, with the first prototype of coated material having already been sent for evaluation.
Thermal spraying is an advanced manufacturing method in which material in powder or wire form is melted and sprayed onto a surface to create a coating with specific properties. The technology enables coatings with specific properties that are crucial for improving products such as electrolysers for the production of green hydrogen. Green hydrogen – produced by the electrolysis of water using renewable energy – plays a central role in the transition to a carbon-free economy. Thermal spraying enables the development and industrial production of key components in an electrolysis stack.
“This investment is part of the company’s long-term strategy to drive innovation and create sustainable solutions. It is a pilot that will primarily be used for research purposes but will also be used for small-scale production when possible. By using this technology in our manufacturing processes, we can offer advanced materials and components that meet the high demands of hydrogen production. This initially includes the development of components for electrolyser cells, but also other applications that require robust and durable coatings,” stated Tom Eriksson, Head of Strategic Research at Alleima.
Alleima anticipates that the adoption thermal spray technology will eventually make it possible to develop products that replace expensive material solutions, thus reducing the cost of electrolyser stacks and, in turn, lowering carbon emissions through the increased use of green hydrogen. The process uses a heated material in powder form that is propelled at high speed onto the surface to be coated. When the powder lands on the surface, the particles deform and solidify. Typically, multiple layers are sprayed onto the surface to achieve the desired properties.
“This is further proof that Alleima continues to be at the forefront of innovation and technical development. Our goal is to create groundbreaking solutions for a cleaner and greener world. We are currently in contact with several potential customers who are testing our prototype material, in their test facilities,” added Mikael Blazquez, EVP and Head of Strategy, M&A and IT at Alleima.
One of the advantages of thermal spraying is that it is a fast process and can be used in many different areas, depending on the base material used. Common materials include metals, metal alloys, composites, and ceramics. These coatings can withstand high temperatures and protect components from wear and corrosion, making them ideal for industrial applications. The coatings can also enhance the properties of the component (e.g. friction, electrical conductivity or insulation).
