Structural & Wear-Resistant Ceramic Coatings

Abstract

Structural and wear-resistant ceramic coatings have become an important class of surface engineering materials due to their excellent hardness, thermal stability, corrosion resistance, and ability to extend the service life of engineering components. These coatings are widely applied in aerospace, automotive, energy, biomedical, and manufacturing industries where components are exposed to severe mechanical, thermal, and chemical environments. This review paper discusses the fundamental aspects of structural and wear-resistant ceramic coatings, including commonly used ceramic materials, deposition techniques, microstructural characteristics, and wear mechanisms. Special attention is given to thermal spray, physical vapor deposition, chemical vapor deposition, and sol–gel based coating methods. The relationship between coating composition, microstructure, and tribological performance is critically analyzed. Recent developments in nanostructured and composite ceramic coatings are also reviewed, highlighting their improved wear resistance and toughness compared to conventional coatings. Challenges related to adhesion, residual stresses, and coating failure are discussed along with future research directions. The paper aims to provide a comprehensive overview useful for researchers and engineers working in surface engineering and advanced ceramics.

KEYWORDS: Ceramic coatings, wear resistance, structural coatings, thermal spray, tribology, surface engineering