Throughout the steel production process, the production hardware is exposed to a combination of high temperatures,
corrosive environments, and wear. This environment produces a broad range of degradation mechanisms and ultimately leads to a reduction in product quality, reduced operating efficiencies, and greater maintenance costs, and downtime. Thermal spraying (TS) has been used to address such steel production challenges since the early 1970s (Ref 1, 2). As the thermal spray hardware and consumable technologies have matured, the number of thermal spray coating solutions in this industry has markedly increased (Ref 3). Thermal spray coatings are now standard in steel production facilities around the world