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Transparent parts with faults down to a tenth of a micrometer lead to reject parts. For processing transparent polymers, injection molding machines (IMMs) are most commonly used. To reduce these faults, plasma vapor deposition (PVD) coatings for injection tools are used in this paper to reduce adhesion, wear, and corrosion. All the investigations were carried out on the two steel types ASTM A422 and plasma‐nitrided ASTM A355. The coatings of TiN, (Ti0.4Al0.6)N, (Ti0.4Al0.6)ON, CrN, (Cr0.6Al0.4)N, and (Cr0.6Al0.4)ON were developed with good adhesion to the substrate. With the PVD coatings of (Ti0.4Al0.6)ON and (Cr0.6Al0.4)ON the lowest adhesion of the polymers to the surface could be realized. These two coatings were applied on screw tips and used. After all the tests were performed, the coated parts could be cleaned much easily from the polymers.

This paper describes a through‐process modelling on a microstructural level of the production of a coated turbine blade, including its in‐service properties and degradation, accompanied by the actual production and testing of a CMSX‐4 single crystal turbine blade dummy. The following steps are dealt with by modelling and experiment: solidification of the blade alloy during casting, microstructural changes during homogenization and aging heat treatments, chemical vapour deposition of an Al2O3 diffusion barrier coating, physical vapour deposition (sputtering) of a (Ni,Co)CrAlY bond coat, atmospheric plasma spraying of an Y2O3 stabilized ZrO2 thermal barrier coating and microstructural changes and development of critical stresses at in‐service conditions. This work forms a part of the Collaborative Research Centre 370 (SFB 370) “Integrative materials modelling”.

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