Tribology coatings for mobility applications - Lesson 3: Tribology coatings for hydrogen applications
Welcome to lesson 3 of the Ionbond Summer School!
Last time, we looked at how DLC coatings are optimized for extremely high loads, such as those encountered in racing or electric mobility.
Today, we'll explore the challenges tribological coatings face in applications involving alternative fuels.
Alternative Fuels in the Mobility Sector
In addition to conventional gasoline, diesel, and natural gas, various alternative energy sources are becoming increasingly important in the mobility sector.
These include hydrogen and hydrogen-containing fuels such as methanol, as well as synthetic fuels, commonly referred to as e-fuels.
E-fuels are fuels produced using renewable energy that can be used in existing engines.
They are particularly relevant in sectors that are difficult to electrify, such as aviation and shipping.
Hydrogen as an energy carrier
Hydrogen can be used in various ways for propulsion.
Hydrogen fuel cell systems
One option is the fuel cell, in which hydrogen reacts with oxygen to form water while generating electricity that is subsequently used for propulsion.
This approach is particularly suitable for long distances and heavy loads, such as long-haul trucks and off-road vehicles, and competes with the increasing range of battery-electric vehicles.
Hydrogen-based combustion fuels
Alternatively, hydrogen and hydrogen-containing fuels such as methanol or ammonia can be burned to provide energy for propulsion.
Because they can be refueled quickly, these solutions are particularly attractive for high-load applications such as mining and off-road vehicles.
Requirements for Coatings in Future Propulsion Systems
The introduction of alternative fuels is changing the operating conditions of many tribological systems. Components such as fuel injection systems, valves, pumps, bearings, and seals are exposed to new chemical environments, altered lubrication conditions, and in some cases increased mechanical loads.
Coatings must therefore not only exhibit a low coefficient of friction and high wear resistance but also meet additional requirements for corrosion resistance and long-term reliability.
E-fuels
E-fuels differ in some respects from conventional fuels in terms of their chemical composition and the additives they contain, which can alter tribochemical reactions at the interface.
Fuel cell systems
Fuel cell systems place high demands on long-term stability while simultaneously requiring maximum corrosion resistance and electrical conductivity.
Hydrogen atmospheres
Hydrogen-containing atmospheres are typically dry, which alters lubrication and temperature control, thereby affecting friction and wear properties.
Furthermore, hydrogen diffusion can lead to hydrogen embrittlement, which must be avoided at all costs to ensure safe long-term operation.
The hydrogen barrier effect therefore represents an entirely new requirement for coating systems.
Download our whitepaper on coatings for Tribological Hydrogen Applications.
Our tribological coatings are the perfect solution for boosting the longevity and efficiency of your injection components, valves, and compressors. Download our whitepaper now for more insights!
You can find a practical example based on a fuel injection system in our whitepaper.
André Hieke
Global Product Manager Mobility
André Hieke
Global Product Manager Mobility
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André Hieke
Global Product Manager Mobility
Ionbond Summer School
Discover all our lessons on the performance-enhancing properties of tribology coatings for mobility applications
Lesson 1: How are tribology coatings designed?
Available on 4. August 2026
In this lesson, we explore how coatings for mobility applications are designed, the factors that must be considered during development, and why DLC coatings provide key advantages for specific application requirements.
Lesson 2: Highly resilient DLC coatings for extreme applications
Available on 11. August 2026
We are diving into highly resilient DLC coatings designed for demanding mobility applications where components are exposed to high loads, increased torque, changing lubrication conditions, and rough counter surfaces.
Lesson 3: Tribology coatings for hydrogen applications
Available on 18. August 2026
We'll explore challenges like corrosion resistance, long-term reliability, stable friction behaviour, and protection against hydrogen diffusion which tribological coatings face in applications involving alternative fuels.
Lesson 4: Coating solutions for aerospace
Available on 25. August 2026
We take a closer look at coating solutions for aerospace and how coating solutions help protect critical parts against wear, corrosion, oxidation, erosion, and fatigue while supporting higher efficiency and longer service life.
Lesson 5: Coating solutions for radar antennas
Available on 1. September 2026
In this lesson, we explore the future of autonomous driving and the role of radar antennas in Advanced Driver Assistance Systems. These critical components require coating solutions that combine strong adhesion, high electrical conductivity, corrosion protection, uniform layer distribution, and cost-effective manufacturing at scale.