The aerospace industry is under unprecedented pressure to deliver lighter, more efficient, and environmentally responsible aircraft engines. As manufacturers push the boundaries of temperature, durability, and emissions control, advanced materials and surface technologies are becoming mission-critical.
In this exclusive interaction, Mr. Anand Golikere, Director – Sales & Operations, Oerlikon Balzers Coating India Pvt. Ltd., shares how Oerlikon’s cutting-edge coatings and process technologies are enabling next-generation aircraft performance while enhancing safety and sustainability across the aviation ecosystem.
Q1. Aerospace manufacturers are demanding higher efficiency and lower emissions. How is Oerlikon contributing to this transformation?
Space constraints are real in Indian manufacturing facilities. Capital efficiency matters.
The new 5-axis Heckert X compact series including X50, X70, X80 and X90 — is designed to machine large and complex aerospace components within optimized floor footprints.
With pallet sizes from 500 mm to 1000 mm, these universal machining centers provide:
- High rigidity
- Maximum precision
- Multi-side machining in a single setup
- Reduced handling time
For Tier 2 suppliers upgrading from 3-axis or basic HMC platforms, this shift to advanced 5-axis machining can dramatically improve:
- Geometric accuracy
- Lead times
- Global certification compliance
Q2. What role do abradable coatings play in improving engine efficiency?
Abradable coatings are a critical part of engine safety and performance. They are used to seal the gas path inside aero engines. By creating tighter clearances, they significantly reduce leakage losses and improve engine efficiency by approximately 1–3%. While this percentage may sound small, in aviation it translates into substantial fuel savings and reduced emissions over an aircraft’s lifecycle.
Moreover, abradable coatings enhance operational safety by ensuring optimized engine function under varying thermal and mechanical stresses. Oerlikon is recognized globally as a leader in this domain.
Q3. The hot section of an engine faces extreme temperatures. How do your coatings address this challenge?
The hot section — particularly the combustor and turbine — operates under extreme conditions. To enable higher temperature operation without compromising material integrity, we deploy advanced thermal barrier coatings (TBCs), environmental barrier coatings (EBCs), and CMAS-resistant coatings.
These coatings protect substrates from temperatures they would not otherwise withstand. Operating at higher temperatures directly improves engine efficiency and reduces fuel consumption.
In simple terms, our coatings act as protective shields, allowing engines to push performance limits safely and reliably.
Q4. Landing gear coating has evolved significantly. How is HVOF technology replacing hard chrome plating?
Traditionally, landing gears were hard chromium plated. However, hard chrome involves environmentally
hazardous processes and has limitations in performance.
Our High Velocity Oxy-Fuel (HVOF) thermal spray coatings not only exceed the performance of hard chrome but also eliminate the environmental concerns associated with hexavalent chromium.
HVOF coatings offer superior wear resistance, corrosion resistance, and durability — meeting the stringent requirements of new-generation aircraft. This transition represents both a performance upgrade and a sustainability milestone for the aerospace industry.
Q5. Oerlikon is also active in aircraft interiors. Could you elaborate on this aspect?
Absolutely. Aircraft interiors demand both aesthetics and functionality. For cockpit instruments, non-reflective surfaces are essential so pilots can clearly observe critical parameters like speed and altitude. Black and grey coatings ensure glare-free readability.
For cabin interiors, we developed BALTONE coatings — offering a wide range of colors while providing superior wear protection and long service life. These coatings combine design flexibility with durability, ensuring interiors remain attractive and high-performing over time.
So whether it’s performance in the engine core or aesthetics in the cabin, our coatings add measurable value.
Q6. How do coatings enhance flight safety beyond engine components?
Safety is at the heart of aerospace engineering. Our coatings significantly reduce friction and sliding wear across various mechanical systems.
For example, flight control systems benefit from reduced seizure risks due to enhanced sliding behavior. Flap adjustment elements operate more smoothly, improving reliability. When you multiply these micro-level improvements across thousands of components, the cumulative impact on safety and operational stability becomes enormous.
Q7. Collaboration seems central to aerospace innovation. How does Oerlikon work with OEMs?
No manufacturer can meet today’s efficiency and sustainability goals alone. Collaboration is essential.
We work closely with aero engine OEMs and component manufacturers from early design stages. By integrating advanced materials science and coating technologies into product development, we help them achieve lighter structures, higher temperature resistance, and improved lifecycle performance.
Our role goes beyond being a coating supplier — we are a technology partner.
Q8. Looking ahead, what excites you most about aerospace advancements?
The next decade will redefine aviation. Sustainability targets, alternative fuels, hybrid propulsion systems, and lightweight composite materials will demand even more advanced surface solutions. What excites me is that coatings — often invisible to the naked eye — are becoming central to achieving global aviation goals. From emission reduction to enhanced passenger safety, advanced materials are silently driving progress.
At Oerlikon Balzers, we are proud to be part of this transformation — enabling aircraft engines and systems to perform better, last longer, and operate more sustainably.