Role of Thermal Spray Coatings on Erosion, Corrosion, and Oxidation in Various Applications: A Review

Depending on the location, extreme environmental conditions must have different graded properties. This is especially important for surfaces that are exposed to mechanical, chemical, thermal, and electrochemical interactions, as these can harm other components in use, such as gas turbines, ball valves, aerospace, power plants, and heat exchangers. The primary problems, such as oxidation, corrosion, erosion, and wear or their combinations will shorten the components life. One of the key deposition methods to address the said issues is thermal spray procedure. Amongst the several thermal spray approaches, the high-velocity oxy-fuel (HVOF) thermal spray technique is frequently used because of its improved performance, cheap expansion costs, and creation of high-density coatings with nominal porosity. In addition to discussing different coating materials and applications, this article provides an overview of advantages and limits of the HVOF spray method. This paper also addresses the impact of varying coating parameters on material significances relating to high-temperature performances, microstructural properties of HVOF spray technique, and electrochemical behaviours. © The Author(s), under exclusive licence to Springer Nature Switzerland AG 2024.