High-temperature boiler systems have several difficulties, such as oxidation, corrosion, and erosion-related material degradation. Thermal spray coatings are crucial for these kinds of issues as well as for boosting the longevity and efficiency of boiler parts. The review paper focuses on the role of thermal spray coatings in boilers, challenges in boiler systems, and the range of thermal spray coating techniques utilized for high-temperature applications. The review illustrates how coatings improve erosion and oxidation resistance by looking at important studies and recent developments. It also talks about new materials and methods that have been developed to solve particular problems with boiler systems. The results highlight the major advantages of thermal spray coatings in raising overall system efficiency, decreasing maintenance costs, and prolonging the life of boiler components. To maximize performance in high-temperature environments and overcome new challenges, coating technologies research and development must continue.
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Shetty et al. (2026) studied this question.
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