Thermal spray coatings are very effective in combating wear and corrosion in many applications. New thermal spray processes and coating compositions continue to be developed with concomitant improvements in the performance of the coatings and their use in new applications. Nonetheless, the thermal spray coatings are not without competition from other coating and overlay processes and materials. This brief review considers the microstructures and the wear and corrosion resistance of a number of alternative coatings to thermal spray coatings, including physical vapor deposition, chemical vapor deposition, electroplating, autocatalytic, and laser cladding.

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