Advanced Coating Systems in High-Temperature Corrosion Protection

High-temperature corrosion presents critical challenges for materials operating in extreme thermal environments, threatening structural integrity and efficiency across aerospace, power generation, and petrochemical industries. This chapter examines protective coating technologies designed to combat oxidation, sulfidation, carburization, and molten salt attack at temperatures exceeding 1000°C. Advanced materials, including thermal barrier coatings (TBCs), environmental barrier coatings (EBCs), high-entropy alloys (HEAs), and self-healing nanocomposites, are analyzed alongside innovative deposition techniques and computational design tools. Through comparative analysis of multi-layered systems, nanostructured composites, and smart coatings, the chapter demonstrates how tailored architecture can extend component lifespans by 60–80% under aggressive conditions. Case studies from aerospace, nuclear, and waste incineration sectors illustrate practical implementations, while emerging trends in ultra-high-temperature ceramics and AI-driven design signal future directions. This comprehensive examination bridges fundamental science with engineering practice, providing a roadmap for developing coatings that balance extreme-environment durability with modern sustainability imperatives.