New cylinder corrosion protection technology with greater flexibility

Photo: Bosch Rexroth laser-based coated cylinder

Introduction of Enduroq 3 proves new laser-based coating process and enables Bosch Rexroth to offer Enduroq protective coatings with more flexibility options

  • No porosity and zero permeability guarantees long lasting surface protection
  • Enables use of CIMS system with hydraulic cylinders in corrosive environments
  • First in series of Enduroq coatings to use laser cladding process

First in a new series of Enduroq coatings, Enduroq 3 is the next generation of the proven Enduroq 3000. Bosch Rexroth, the leading company in drive and control solutions, together with the Fraunhofer institute, Europe's largest application-oriented research organization, developed a laser cladding technology to supersede the traditional arc welding process. Laser cladding enables faster production of coatings with more flexibility in materials. The move was made in response to demand for more flexible protective coatings.

Until recently, the Enduroq 3000 and 3200 coatings were applied to offer a highly corrosion-resistant layer, excellent in very aggressive environments like offshore applications. This coating was applied by using electric arc, or plasma transferred arc (PTA), which welds the Ultimet powder onto the cylinder. However, the process was time consuming and had limited flexibility for using other powders. Therefore, it could not be extended to other businesses.

“What’s more, the PTA process cannot be used with our CIMS (Cylinder Integrated Measuring System) which, due to its high accuracy and multiple data features, is a very popular implementation on our hydraulic cylinders,” said Michiel Kuijper from Bosch Rexroth. “To overcome these challenges, we have worked with the Fraunhofer Institute over the last two years to develop the new laser-based process.“

Thanks to increased laser power, laser technology is at the forefront of new piston rod coating developments. And the new Rexroth Enduroq coatings utilize the highest power laser in the industry. The 20 kw machine located in Boxtel is one of the most powerful of its kind. It is equipped with a large head that allows faster production of the coating.

For the new Enduroq 3 layer, Rexroth uses the laser cladding process to weld a cobalt based alloy (Ultimet) onto a steel rod. Piston rods up to 600 mm diameter can be equipped with the welded overlay. Characteristics match those of the Enduroq 3000 series, although the layer is applied via an improved coating process as the technology is more tunable and can utilize different laser temperatures. Also, unlike the PTA process, laser cladding can be used to coat the grooved surfaces needed by CIMS. This means more applications, including those involving harsh environments, can implement Rexroth’s positioning measuring and condition monitoring device.

Enduroq 3 is ideal in applications where mechanical impact is higher. It offers optimal cylinder functionality in high corrosion industries such as deep water offshore drilling. A single layer surface technology, Enduroq 3 has no porosity and zero permeability, guaranteeing long lasting surface protection. This means minimal downtime, along with easier maintenance in the field.


Economical, precise, safe, and energy efficient: drive and control technology from Bosch Rexroth moves machines and systems of any size. The company bundles global application experience in the market segments of Mobile Applications, Machinery Applications and Engineering, and Factory Automation to develop innovative components as well as tailored system solutions and services. Bosch Rexroth offers its customers hydraulics, electric drives and controls, gear technology, and linear motion and assembly technology all from one source. With locations in over 80 countries, more than 29,500 associates generated sales revenue of approximately 5 billion euros in 2016.

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The Bosch Group is a leading global supplier of technology and services. It employs roughly 390,000 associates worldwide (as of December 31, 2016). The company generated sales of 73.1 billion euros in 2016. Its operations are divided into four business sectors: Mobility Solutions, Industrial Technology, Consumer Goods, and Energy and Building Technology. As a leading IoT company, Bosch offers innovative solutions for smart homes, smart cities, connected mobility, and connected manufacturing. It uses its expertise in sensor technology, software, and services, as well as its own IoT cloud, to offer its customers connected, cross-domain solutions from a single source. The Bosch Group’s strategic objective is to deliver innovations for a connected life. Bosch improves quality of life worldwide with products and services that are innovative and spark enthusiasm. In short, Bosch creates technology that is “Invented for life.” The Bosch Group comprises Robert Bosch GmbH and its roughly 440 subsidiaries and regional companies in some 60 countries. Including sales and service partners, Bosch’s global manufacturing and sales network covers nearly every country in the world. The basis for the company’s future growth is its innovative strength. At 120 locations across the globe, Bosch employs some 59,000 associates in research and development.

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Vincent Stahlecker
Kruisbroeksestraat 1
5281 RV Boxtel, the Netherlands
Phone: +31 411 651 682

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