Coatings and surface engineering – protection, performance, and sustainability for extreme environments

TWI offers world-leading expertise in coatings and surface engineering, covering the full spectrum from thin surface modifications to thick protective claddings. Our work helps industries enhance component performance, extend service life, and meet evolving sustainability requirements.

At one end of the scale, ion implantation, nitriding, and aluminising modify only a thin surface layer (0.001–1 mm) to improve hardness, wear resistance, or oxidation behaviour. At the other, weld hardfacing and cladding processes (1–20 mm) deliver robust protection and allow for the repair and restoration of high-value components.

Between these extremes, TWI develops and validates a broad range of deposition techniques, including PVD, CVD, anodising, laser processing, thermal spraying, cold spraying, and liquid deposition methods. We support material and process selection, coating performance validation, and failure analysis, offering fully impartial consultancy thanks to our independence from equipment and consumable suppliers.

Our multidisciplinary research teams help industry address critical challenges such as replacing legacy coatings restricted for environmental or health reasons, and developing next-generation protective and functional coatings for space, aerospace, energy, and defence applications.

From thin films for optical and thermal control to thick coatings for erosion, corrosion, or radiation shielding, TWI provides the expertise, facilities, and innovation needed to deliver fit-for-purpose, sustainable coating solutions for the most demanding environments.