Corrosion and surface degradation are critical challenges in industries operating under aggressive service conditions, including petrochemical, glass manufacturing, mining, and steel production. This presentation reviews the application of advanced thermal spray technologies—specifically Flame Spraying, High-Velocity Oxy-Fuel (HVOF), Plasma Spraying, Plasma Transferred Arc (PTA) Welding, and Laser Cladding—used to improve the corrosion resistance and durability of critical components. Drawing upon data from industry-standard alloy powders, the review focuses on the role of nickel-, cobalt-, and tungsten carbide-based compositions enriched with chromium, boron, and silicon. These chemistries contribute to improved hardness, low porosity, minimal dilution, and strong metallurgical bonding and also corrosion resistivity. Relevant industrial case examples, including mold repair in glass manufacturing and valve coating in oil and gas systems, are used to demonstrate the effectiveness of these processes in enhancing corrosion resistance. This work highlights the importance of thermal spray welding process in achieving long-lasting surface protection in corrosive environments.
