R2S Tec
R2S Tec

We electrify heat.

Heat generation in times of renewable energy sources will need resisitive heating concepts. By thermal spray, we can create electrical heating on nearly every surface.

Fully integrated. Fast heatup. High temperatures.

R2S Tec

Principle

In resistive heating, electrical energy is converted directly into heat within the heating conductor. The power dissipated follows Joule’s law:

P = I² · R

The electrical resistance R depends on the material and on the length and cross-section of the conductor (R = ρ · l / A). Heating power and operating temperature can therefore be tailored through material, geometry and current.

R2S Tec

Materials

Heating conductors require high specific resistance, sufficient high-temperature strength and a stable, protective oxide layer.

  • NiCr 80/20 (Ni20Cr): Nickel-chromium alloy with high oxidation and corrosion resistance, service temperature up to approx. 1200 °C in air.
  • FeCrAl: Iron-chromium-aluminium alloy that forms a stable aluminium oxide layer. Service temperature up to approx. 1300–1400 °C; a cost-effective alternative to NiCr alloys.
  • MoSi₂: Molybdenum disilicide for the highest temperatures, up to approx. 1700–1800 °C in air. It forms a protective SiO₂ layer but is brittle and has limited mechanical load capacity.
  • Inconel (e.g. Inconel 600): Nickel-chromium-iron superalloy with high strength and corrosion resistance, service temperature up to approx. 1100 °C. Commonly used in sheathed heating elements and under corrosive conditions.
R2S Tec

Applications

  • Fully integrated heating: Heating conductors are integrated directly into components, tools, moulds or equipment, e.g. injection moulding tools, heating plates and extruders.
  • E-mobility: Cabin heating, seat and window heating, and battery temperature control.
  • Aerospace: De-icing and anti-icing of windows, wings and sensor systems such as pitot tubes.
  • Pipelines: Heat tracing for frost protection and for maintaining process temperatures of media such as oils and waxes.
  • Further fields: Industrial furnaces, household appliances, medical technology, analytical instruments and food processing.
R2S Tec

Advantages over Conventional Heating

  • Improved heat transfer: Heat is generated exactly where it is needed. Intermediate transfer steps via heat carrier media are eliminated.
  • Light and compact design: No boilers, pumps or heat carrier circuits, resulting in low volume and weight.
  • Cost-effective manufacturing: Fewer components and simpler assembly.
  • Use in 3D structures: Heating conductors can be adapted to complex geometries and curved surfaces.
  • Retrofit heating: Heating systems can be added to existing components and installations.