Thermal spray coatings on high-temperature oxidation and corrosion applications – A comprehensive review

In high-temperature boiler operations, conventional steels and alloys grapple with the formidable challenges posed by oxidation and corrosion. Prolonged exposure to extreme thermal conditions exacerbates these issues, progressively diminishing operational efficiency. Surface treatment emerges as a pivotal strategy for safeguarding materials against deterioration while optimizing component performance cost-effectively. Recent attention has honed on surface coatings as a means to combat hot corrosion in boiler steels. Thermal coating, electroplating, and other metallurgical techniques are widely embraced for surface modification, with composite coatings gaining traction for bolstering metallurgical, mechanical, and corrosion resistance properties. This review, unlike any other, takes a comprehensive approach to exploring various thermal spraying methods and their applications, ensuring a robust understanding of the subject matter. Beyond a mere compilation of existing literature, this review identifies emerging trends and technologies, offering fresh insights and interpretations. In this work, 84 articles were critically evaluated for current research, discerning strengths, weaknesses, and avenues for future research on thermal spray coatings on high-temperature oxidation and corrosion. This incisive approach promises to enrich the knowledge base of researchers, scholars, and professionals in materials science, metallurgy, and industrial engineering, facilitating advancements in the field. By pinpointing research gaps in thermal spray coating, this study directs attention toward areas ripe for further investigation, fostering continued innovation and progress. •Hot corrosion is a major issue for boiler steels in thermal power plants.•Achieving defect-free thermal spray coatings is challenging due to inherent porosity and micro-cracks.•Solid lubricants in thermal spray coatings reduce friction, and wear, and extend component lifespan.•Nanostructured and rare earth materials show promise, but further research is needed.•Additional heat treatment enhances coatings' corrosion and wear resistance.