Nanocomposite Hybrid Coatings for Hot Corrosion Resistance: Mechanisms, Materials, and Experimental Insights

DOI

10.2991/978-94-6239-750-7_68How to use a DOI?

Keywords

Hot corrosion; preventive coatings; thermal spray; porosity; Nanocomposite hybrid coatings

Abstract

The process of hot corrosion is a critical barrier to the durability and operational efficiency of high-temperature components in power generation, aerospace, and marine applications. This research presents an extensive review of the underlying principles, classification, and mitigation strategies applicable to hot corrosion, with particular emphasis on Type I (High-Temperature) and Type II (Low-Temperature) modes dominated by molten salts like Na_₂SO_₄ and V_₂O_₅. Emphasis is placed on innovative protective approaches, namely thermal spray processes and hybrid nanocomposite coatings, with the toughness of metallic matrices and thermal stability of ceramic additives. Sophisticated hybrid configurations like MCrAlY + YSZ, cermet metal composites, and metal-ceramic nanostructured systems exhibit excellent resistance to degradation by oxide scale, salt penetration, and thermal cycling effects. Porosity role, microstructural characteristics of coatings, and the incorporation of rare-earth elements in improving corrosion resistance are thoroughly reviewed. Moreover, cutting-edge experimental techniques like TGA, HT-XRD, SEM/EDS, electrochemical assessments, and realistic furnace simulations are presented for their potential in coating performance evaluation in extreme conditions. Recent research findings present the potential of nanostructured coatings, two-dimensional nanomaterials, and self-healing films as potential solutions to advanced corrosion protection. Overall, this study presents an extensive strategic framework for the design, optimization, and evaluation of high-performance coatings for imparting hot corrosion mitigation in extreme operational conditions.

Copyright

© 2026 The Author(s)

Open Access

Open Access This chapter is licensed under the terms of the Creative Commons Attribution-NonCommercial 4.0 International License (http://creativecommons.org/licenses/by-nc/4.0/), which permits any noncommercial use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license and indicate if changes were made.

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TY  - CONF
AU  - Dilpreet Singh
AU  - Davinder Singh
AU  - Harvinder Singh
AU  - Khushdeep Goyal
PY  - 2026
DA  - 2026/08/31
TI  - Nanocomposite Hybrid Coatings for Hot Corrosion Resistance: Mechanisms, Materials, and Experimental Insights
BT  - Proceedings of the International Conference on Advanced Design, Manufacturing, and Sustainable Energy Systems (ICADMSES 2026)
PB  - Atlantis Press
SP  - 953
EP  - 972
SN  - 2589-4943
UR  - https://doi.org/10.2991/978-94-6239-750-7_68
DO  - 10.2991/978-94-6239-750-7_68
ID  - Singh2026
ER  -