Clean energy is no longer a future goal, it’s happening now. From capturing carbon and creating sustainable fuels, to powering next-generation batteries and nuclear systems, the world is racing to scale technologies that can withstand extreme environments.

But here’s the catch: many of these systems operate at temperatures above 700 °C, in sulphur-rich or corrosive conditions where most materials would quickly fail. So how are reactors lasting longer, batteries cycling further, and fuel cells powering up more reliably?

The answer lies in a quiet hero of clean technology: advanced diffusion coatings.

The Coatings Powering the Future of Clean Technology

Clean technology is moving faster than ever.

Reactors now run at 700–900 °C in sulphur-rich environments.
Batteries are being pushed to 500–600 °C to unlock higher energy density.
Fuel cells operate above 700 °C, cycling constantly through heat and corrosive gases.
Nuclear components face radiation-assisted corrosion for years at a time.
These are some of the harshest environments on the planet. And yet, components are lasting longer, systems are running more reliably, and new clean technologies are scaling up at speed.

The reason isn’t always obvious. Behind the scenes, advanced diffusion coatings make these breakthroughs possible.

Turning Carbon into Fuels

From carbon capture and utilisation through to sustainable aviation fuel, today’s clean-fuel technologies push equipment to the limit. Reactors are exposed to sulphur-bearing gases, steam, and corrosive feedstocks at extreme temperatures.

Our diffusion coatings, including aluminizing and chromizing, form protective alumina or chromia barriers that slow oxidation, carburisation and sulfidation. The impact is longer component life, fewer unplanned outages and more stable operation in high-value systems.

Batteries That Last Longer

Next-generation batteries and electrochemical reactors are racing towards higher energy density and more sustainable chemistries. Higher performance brings higher stresses, which can compromise durability.

Our boronizing technology creates ultra-hard, corrosion-resistant boride layers. These protect against acid attack and wear, giving critical components the resilience they need in environments up to around 500–600 °C. Every extra cycle of durability helps accelerate electrification and diffusion coatings deliver it.

Stronger Catalysts, Better Chemistry

Catalyst-driven processes sit at the heart of green chemistry and low-carbon fuel production. Yet the reactors and supports that host these catalysts face continuous attack from heat and corrosive gases.

Aluminized and chromized coatings provide proven defence. By forming stable oxide layers, they protect reactor internals and critical surfaces, extend service life and cut downtime. The result is stronger catalysts, better chemistry and lower operating costs.

Reliability in Nuclear Systems

In nuclear power, reliability is non-negotiable. Components must withstand aggressive coolants, radiation-assisted corrosion and extreme heat over long lifetimes.

Diffusion coatings such as aluminides and chromides create metallurgical bonds that resist oxidation, sulfidation, and carburisation even at 800–900 °C. By extending lifetimes and limiting degradation, they help nuclear operators improve both safety and efficiency.

Enabling Clean Power with SOFC

Solid Oxide Fuel Cells promise efficient, flexible, modular clean power. Operating above 700 °C, their metallic interconnects and supports face relentless oxidation and corrosive atmospheres.

Our coatings form dense, adherent oxide barriers that limit degradation under both steady-state and thermal cycling conditions. With the right design, SOFC stacks last longer, run more efficiently and need fewer costly replacements. This is how materials science helps enable the clean-power infrastructure of tomorrow.

Materials Science, Quietly at Work

At Diffusion Alloys we help clean-technology industries operate where few materials can survive. From carbon capture to advanced batteries, catalytic reactors to nuclear protection and fuel cells to next-generation power systems, our coatings provide reliable defence against oxidation, carburisation, sulfidation and wear.

Breakthrough technologies demand durability, efficiency, and resilience. Diffusion coatings quietly provide all three.

Get in Touch

If you are developing technology that must withstand extreme heat and chemical attack, we’d love to talk. Get in touch with our team to explore how diffusion coatings can support your project.