Research status and prospects of Ni-based coatings fabricated by thermal spraying technology

This paper first systematically reviews the preparation technologies for thermally sprayed Ni-based coatings, including flame spraying, arc spraying, plasma spraying, and the novel plasma-enhanced high-velocity arc spraying. Secondly, it analyzes the regulatory effects of various preparation techniques on the coating microstructure and properties, revealing the intrinsic relationship between microstructure and service performance. Thirdly, it summarizes performance enhancement methods such as heat treatment and the introduction of reinforcing phases. Finally, it points out that current technologies still face bottlenecks including difficulty in controlling intrinsic defects, large fluctuations in interfacial bonding, unclear fatigue failure mechanisms, and complex multi-factor coupled damage.