Thermal spray coatings are a group of coating processes that enhance the performance of parts by adding functionality to surfaces. In the past few decades, thermal spray coatings technology was used to resist wear, erosion, corrosion, cavitation, repair and dimensional restoration of parts. However, the consideration of process parameters setting develops a reliable coating having high mechanical and morphological properties for demanding coating applications. Hence the aim of this review paper is to provide an overview of distinct thermal spray coatings, historical development, hot corrosion mechanism and effect of chemical composition and alloying elements on the hot corrosion resistance of super alloys in USC power plants. Then the effects of processing conditions on the mechanical properties of distinct thermal sprayed coatings obtained at distinct process parameters are summarised. Finally, the distinct thermal post treatments such as fusing of self-flux alloys, remelting and solid heat treatments, merits, demerits and future challenges are discussed.
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