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<p>Ceramic coatings are extensively employed to enhance the performance and service life of engineering components due to their exceptional properties, including high hardness, thermal shock resistance, wear resistance, and corrosion behavior. The performance of these coatings is critically influenced by the selection of deposition techniques and their associated process parameters. This review presents a comprehensive assessment of ceramic coating technologies, emphasizing the relationship between processing parameters, coating microstructure, and resultant properties. Key deposition methods such as flame spray, plasma spray, high-velocity oxy-fuel spray, and centrifuge-assisted self-propagating high-temperature synthesis (SHS) are discussed, with particular attention to their ability to produce dense, crack-free ceramic coatings. The effects of variables including spraying power, stand-off distance, jet velocity and temperature, rotational speed, and the incorporation of additives in SHS are analyzed in terms of their influence on ceramic particle deposition. The role of advanced suspension systems in improving microstructural homogeneity is also highlighted. Furthermore, the review explores the advancement of coating systems such as cold-sprayed and glass–ceramic composite bond coatings, which demonstrate superior performance in thermal barrier applications. Finally, emerging trends and future directions in ceramic coating technologies are outlined, focusing on overcoming current limitations and advancing multifunctional coating systems for next-generation engineering applications.</p>

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Comprehensive Insights into Ceramic Coatings: Methods, Properties, and Multifaceted Applications

  • 期刊论文

  • 发表日期：

    2025年9月15日

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  • N. Radhika,
  • M. Sabarinathan,
  • S. Ragunath,
  • M. Ramu,
  • M. Ravichandran

摘要

Ceramic coatings are extensively employed to enhance the performance and service life of engineering components due to their exceptional properties, including high hardness, thermal shock resistance, wear resistance, and corrosion behavior. The performance of these coatings is critically influenced by the selection of deposition techniques and their associated process parameters. This review presents a comprehensive assessment of ceramic coating technologies, emphasizing the relationship between processing parameters, coating microstructure, and resultant properties. Key deposition methods such as flame spray, plasma spray, high-velocity oxy-fuel spray, and centrifuge-assisted self-propagating high-temperature synthesis (SHS) are discussed, with particular attention to their ability to produce dense, crack-free ceramic coatings. The effects of variables including spraying power, stand-off distance, jet velocity and temperature, rotational speed, and the incorporation of additives in SHS are analyzed in terms of their influence on ceramic particle deposition. The role of advanced suspension systems in improving microstructural homogeneity is also highlighted. Furthermore, the review explores the advancement of coating systems such as cold-sprayed and glass–ceramic composite bond coatings, which demonstrate superior performance in thermal barrier applications. Finally, emerging trends and future directions in ceramic coating technologies are outlined, focusing on overcoming current limitations and advancing multifunctional coating systems for next-generation engineering applications.