Electrochemical performance of thermal spray coatings for energy storage devices: A review

Thermal spray coatings have been identified as a potential method for improving the electrochemical performance of energy storage devices, such as batteries, supercapacitors, and fuel cells. This survey presents a synthesis of recent investigations into the use of thermal spray coating in such devices, and also points out the development of coating materials, deposition methods, and microstructural manipulation. Metal alloys with nickel-cobalt-chromium have been used as electrode materials with very high specific capacitances, cycling stabilities, and energy/power density values having been recorded. The dielectric properties, chemical stability, and capacity maintenance of ceramics, such as Al₂O₃, TiO₂, and ZrO₂, have also shown better results when used in batteries. Carbon-based electrodes in spray-coated form, such as multiwalled carbon nanotubes and graphene aerogels, have demonstrated high power and long-term durability in supercapacitors. The rationalization of the thickness of the coating, porosity, and interfacial adhesion process plays an instrumental role in determining the desired electrochemical properties. Nevertheless, it is not without its difficulties in terms of managing microstructural defects, the uniformity of coatings, and their industrial scaling up. Future plans include developing advanced coating materials, novel spray technologies, and modeling systems to circumvent present-day constraints and explore the potential of thermal spray coatings in next-generation energy storage devices. Further investigation of thermal spray coatings presents possibilities for energy-saving, high-performance, durable, and sustainable energy storage applications in the future.