Kalluri Anusha, Shanta Chakrabarty, Bharat Chandra Routara, Nikhil Kumar, Spandan Guha
Abstract The High Velocity Oxyfuel (HVOF) system has established itself as a leading process for depositing NiCoCrAlY and MCoCrAlX coatings, which serve as a crucial bond coat in the Thermal Barrier Coating system (TBC) for high temperature applications. By providing exceptional protection against hot corrosion, oxidation and wear, these coating have become ideally suited for aerospace components and gas turbine applications. Recent advancements have primarily focused on enhancing coating performance through strategies such as pre-oxidation, implementation of multilayers and graded structures, vacuum heat treatment, rare earth doping and oxide dispersion strengthening. These modifications ultimately result in improved grain refinement, adhesion, superior thermal stability and enhanced mechanical properties. This article will provide significant development in HVOF-sprayed MCrAlX/NiCoCrAlY coatings with particular focus on microstructural evolution, durability and process optimization under extreme environmental conditions.