Protective Coatings for High-Temperature Applications: Challenges and Innovations

Notice

This is an unedited manuscript accepted for publication and provided as an Article in Press for early access at the author’s request. The article will undergo copyediting, typesetting, and galley proof review before final publication. Please be aware that errors may be identified during production that could affect the content. All legal disclaimers of the journal apply.

Year : 2025 | Volume : 12 | 02 | Page :
    By

    Rakshita Chaudhary,

  • Neha Rana,

  1. Senior Technical Assistant, Central Drugs Standard Control Organisation, New Delhi, India
  2. Microbiologist, Institute of Industrial Research and Toxicology, UPSIDC, New Delhi, India

Abstract

High-temperature environments impose significant challenges on materials used in a variety of industrial applications, where components are exposed to extreme heat. These environments can cause a range of issues, including material degradation through processes like corrosion, oxidation, and thermal cycling, which can severely limit the performance, durability, and overall lifespan of components. Over time, these issues may lead to component failure, increased maintenance costs, and even unplanned shutdowns in industrial settings. One of the most effective methods to combat these challenges is the use of protective coatings, which act as a shield between the high-temperature surface and the harsh environmental conditions. These coatings provide an additional layer of defense that helps prevent or slow down the degradation processes, such as oxidation and corrosion, that commonly occur at elevated temperatures. In addition to offering corrosion resistance, protective coatings also help in minimizing wear and improving the overall mechanical properties of materials under extreme conditions. The development of high-temperature protective coatings has made significant advancements in recent years, driven by the need for improved performance and longer lifespans in critical applications such as aerospace, energy, and manufacturing industries. These advancements have led to the introduction of novel coating materials, innovative application methods, and enhanced coating designs. However, challenges remain in terms of achieving optimal performance in diverse high-temperature environments, especially in terms of coating adhesion, longevity, and resistance to extreme conditions. This review article aims to delve into these recent advancements, highlighting the innovations in protective coatings, while also addressing the ongoing challenges faced in their development and implementation for high-temperature applications. The future of protective coatings will likely see even more sophisticated solutions that can withstand the ever-increasing demands of modern industrial processes.

Keywords: Thermal Barrier Coatings, Oxidation Resistance, Wear-Resistant Coatings, Self-Healing Coatings, High-Temperature Durability, Nanostructured Coatings

How to cite this article:
Rakshita Chaudhary, Neha Rana. Protective Coatings for High-Temperature Applications: Challenges and Innovations. Journal of Thin Films, Coating Science Technology & Application. 2025; 12(02):-.
How to cite this URL:
Rakshita Chaudhary, Neha Rana. Protective Coatings for High-Temperature Applications: Challenges and Innovations. Journal of Thin Films, Coating Science Technology & Application. 2025; 12(02):-. Available from: https://journals.stmjournals.com/jotcsta/article=2025/view=202874


References

  1. Zhang Y, Wang X, Li Z, et al. Recent advancements in high-temperature protective coatings. Mater Sci Eng R. 2021;138:1-16. doi: 10.1016/j.mser.2020.100562.
  2. Gupta A, Rajendran S. Ceramic coatings for high-temperature applications: A review. J Therm Spray Tech. 2020;29(7):1365-1376. doi: 10.1007/s11666-020-01010-x.
  3. Lee C, Park J, Choi Y, et al. Nanostructured coatings for high-temperature applications: Challenges and innovations. Adv Mater Sci Eng. 2020;2020:3412342. doi: 10.1155/2020/3412342.
  4. Lu S, Wang W, Zhang Q, et al. Multi-layered coatings for high-temperature protection: A review. Corrosion Sci. 2021;178:108955. doi: 10.1016/j.corsci.2020.108955.
  5. Patel A, Singh R. Self-healing coatings: An emerging technology for enhancing the durability of high-temperature materials. Prog Mater Sci. 2021;118:100753. doi: 10.1016/j.pmatsci.2020.100753.
  6. El-Hag S, Li Y, Chan F, et al. Advances in wear-resistant coatings for high-temperature applications. Tribol Int. 2021;151:106579. doi: 10.1016/j.triboint.2020.106579.
  7. Hegde N, Pandya D, Patil S, et al. Advanced ceramic coatings for high-temperature corrosion protection: A review. J Mater Sci. 2020;55(18):7897-7918. doi: 10.1007/s11041-020-03262-3.
  8. Prasad V, Kumar S, Yadav S. Thermal barrier coatings for advanced power systems: Materials and applications. J Therm Spray Tech. 2020;29(8):1407-1422. doi: 10.1007/s11666-020-00980-2.
  9. Zhou J, Zhang L, Wei X. Functionally graded coatings for high-temperature applications: State-of-the-art review. J Mater Sci. 2021;56(12):6711-6728. doi: 10.1007/s11041-021-03389-7.
  10. Liu H, Wang Z, Li J, et al. Design and performance of high-temperature oxidation-resistant coatings for turbine blades. Surface Coat Technol. 2020;394:125847. doi: 10.1016/j.surfcoat.2020.125847.
  11. Kim J, Seo K, Park D, et al. A review of self-healing materials and coatings for high-temperature applications. Int J Appl Ceram Technol. 2021;18(4):1201-1217. doi: 10.1111/ijac.13605.
  12. Kumar S, Sharma P. Wear-resistant coatings for high-temperature components: Review and recent developments. J Mater Sci Technol. 2020;56:1137-1155. doi: 10.1016/j.jmst.2020.06.013.
  13. Mohanty M, Dey P, Bhattacharya A, et al. Thermal barrier coatings: Current status and future trends. J Therm Spray Tech. 2020;29(6):1155-1169. doi: 10.1007/s11666-020-00969-x.
  14. Zhao Z, Liu J, Yang C, et al. Innovations in high-temperature protective coatings for aerospace applications. Aerospace Sci Technol. 2020;101:105816. doi: 10.1016/j.ast.2020.105816.
Ahead of Print Subscription Review Article
Volume 12
02
Received 09/02/2025
Accepted 13/02/2025
Published 06/03/2025
Publication Time 25 Days
374

Login


My IP

PlumX Metrics