A comparative review on cold sprayed cermet coatings and their applications in high temperature corrosion, oxidation and wear resistance

This review article explores the properties and bonding mechanisms specific to cold sprayed cermet coatings, highlighting its contrast with that of pure metals, and pure ceramics. The general cost structure of cold spraying is compared with other thermal spray techniques and the advantages are highlighted. Several cold sprayed cermet coatings with good corrosion, oxidation and wear resistance behavior in elevated temperatures show convincing potential for applications in power generation industries. The important factors that are attributed to producing highly functional cold sprayed cermet coatings are discussed. A strategic approach involving material, equipment, and application specific optimization of the cold spray process is currently relevant and of utmost importance to meet the coating requirements in several industrial applications. • In view of recent findings, the properties and bonding mechanisms of cold sprayed cermet coatings are systematically compared with cold sprayed metal-based and ceramic coatings, • Key factors that influence the microstructural, mechanical, and corrosion performance of cold sprayed cermet coatings, especially in demanding environments are identified, • The importance of CS process parameters optimization, cermet material design, and customization of post spray heat treatments is conferred.