Phosphate-free wire coating without compromising performance – A new coating approach for the wire industry

4 May 2026 |

The demand for surface solutions that are both sustainable and high-performance is growing - especially in the wire and forming industries. Regulatory requirements, stricter environmental regulations, and demanding forming processes are increasingly challenging established coating systems. Against this backdrop, voestalpine Wire Technology has developed a new phosphate-free wire coating that specifically combines sustainability and performance.

What began with initial trials on two 300-kg coils has since grown into a large-scale industrial test. Coating trials for 22 client companies are currently being conducted at the voestalpine Wire Technology site - with support provided directly at the respective facilities. The broad participation of renowned European manufacturers clearly demonstrates that there is a demand for high-performance, phosphate-free alternatives, as well as an expectation of measurable customer benefits.

Management and Experts in the video:

Gunter Korp, Chief Technology Officer (CTO), voestalpine Wire Technology
Michael Staber, Senior Project Manager, voestalpine Wire Rod Austria
Anton Trautmann, Process Engineer - Surface Technology, voestalpine Forschungsservicegesellschaft Donawitz

Staber: We started with small experiments with two 300 kg rings and are here today at the site for a large experiment, where we carry out coating experiments for 22 of our customers, where we are then at the plants to see how these coatings perform. So, you can already see that if 22 well-known manufacturers in Europe join such an experiment, that the demand is there and that everyone expects a customer benefit.

Korp: The task for our research and development department was to develop a new type of coating, which on the one hand includes the sustainability aspect, i.e. the avoidance of heavy metals in the surface coating, and on the other hand to ensure lubrication properties that provide the best possible results for highly complex conversion steps.

Trautmann: The first attempts show that we can really keep up with the performance with the conventional phosphate soap system, a system that has been in use for almost 100 years and is the absolute benchmark, and that we also have significantly better performance than the conventional phosphate-free alternatives that are already on the market.

Staber: Through this new coating system, we expect to take another step forward for the entire Wire Technology portfolio, because we can also cover the topic of surfaces in addition to our expertise in the manufacturing competence of wire production, and therefore differentiate very strongly from our competitors.

Trautmann: A special moment was during development, when we had our coatings tested externally and the results were compared with an international ring test, where many well-known manufacturers participated and our coating was absolutely at the top.

phreeco® – the phosphate-free wire coating

Technical details about phreeco®, the phosphate-free wire coating, its applications, and properties can be found on our phreeco® product page.

Development with a clear objective

The central task for research and development was clearly defined: to develop a novel coating that does not contain heavy metals while simultaneously delivering the lubricating properties required for highly complex forming processes. The bar was set high - because the reference is a system that has served as an industrial benchmark for nearly 100 years: the classic phosphate-soap system.

Test results to date show that the new coating holds its own in practice. In tests, it achieves a performance level comparable to that of the established phosphate system - while significantly outperforming the phosphate-free alternatives previously available on the market.

Initial tests show that we can match the performance of the classic phosphate-soap system - a system that has served as an industry benchmark for nearly 100 years. At the same time, we are achieving significantly better results than previously available phosphate-free alternatives on the market.

Anton Trautmann, Process Engineer – Surface Technology, voestalpine Forschungsservicegesellschaft Donawitz

Verification through external testing

A decisive milestone in the development process was external validation. The new coating was tested as part of an international interlaboratory test in which numerous renowned manufacturers participated. The results confirmed the internal findings of: The solution from voestalpine Wire Technology ranked at the top of the field in terms of performance.

"A particularly special moment actually came during the development process when we had our coating tested externally and the results were compared in an international interlaboratory test, in which a great many well-known manufacturers participated and our coating was absolutely at the top of the pack," emphasizes Anton Trautmann, Process Engineer – Surface Technology, voestalpine Research Service Company Donawitz

This external validation underscores not only the technical maturity of the system but also its relevance for industrial applications under real production conditions.

More than just material expertise

With the new coating, voestalpine Wire Technology is strategically expanding its portfolio. In addition to its established expertise in material design and wire production, the company is placing greater emphasis on surface technology. The goal: to support customers not only with the right material, but with integrated solutions across the entire value chain.

This opens an additional differentiator in the market - especially for applications where sustainability, process stability, and forming performance are equally critical.

Outlook

Ongoing large-scale trials with customers provide valuable insights into the further industrialization of the coating. The goal is to provide a high-performance alternative to traditional phosphate systems that meet both environmental requirements and the high technical demands of modern forming processes.

This development exemplifies how sustainable material concepts and industrial performance can be combined - not as a compromise, but as the next evolutionary step in wire coating.

Do you have a new project that requires a phosphate-free coating?

Our experts will be happy to advise you and find the right solution for your needs!