Coatings deposited utilizing different thermal spray variants have been widely used for diverse industrial applications. Today, various coating techniques belonging to the thermal spray family and spanning a vast cost–quality range have been embraced by the industry to either extend the longevity of components or enhance their performance, especially when these parts routinely operate in harsh conditions. The current state-of-the-art route for depositing the ceramic coatings is usually atmospheric plasma spraying (APS), while metallic and intermetallic coatings are sprayed by high-velocity oxy-fuel (HVOF) methods. Between them, the above spray methods and the vast portfolio of commercially available spray grade powders are capable of providing coatings that can combat premature surface degradation when industrial components are exposed to wear, corrosion, oxidation, high thermal load, etc. The immense versatility of the technique has already led to its numerous industrial uses, ranging from the advanced gas turbine requirements to the relatively more mundane needs of sectors such as textile, mining, pulp and paper and petrochemical sectors.
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