Innovative Coatings for a Greener Sky: The 2026 Strategic Roadmap for Thermal Spray and PVD Coatings

Andrew Ang; Thibaut Archer; Farzam Arhami; Mettupalayam Balachander; Kantesh Balani; Dominique Billières; Ann Bolcavage; Giovanni Bolelli; Marjorie Cavarroc-Weimer; Sophie Costil; Nicholas Curry; Alain Denoirjean; Ali Dolatabadi; Alice Dolmaire; William Duarte; David Dublanche; Julien Escobar; Alice Fabre; Gaël Fick; Guillaume Fradet; Frank Gärtner; Edward J. Gildersleeve; Mohit Gupta; Jonathan Gutleber; Makoto Hasegawa; Bryan J. Harder; Brian Hazel; Hendrik Heinemann; Xianghui Hou; Tanvir Hussain; Eric Irissou; Mehdi Jadidi; Cédric Jaoul; Maria Ophelia Jarligo; Bertrand Jodoin; Shrikant Joshi; Andreas Killinger; Jolanta E. Klemberg-Sapieha; Komal Laul; Chang Jiu Li; André C. Liberati; Rocco Lupoi; Gilles Mariaux; Ludvik Martinu; André McDonald; Christian Moreau; Majid Nabavi; Aleksandra Nastic; Ahmet Hilmi Paksoy; Cédric Poupon; Vincent Rat; Óscar Rojas; Céline Ruelle; Pierre Sallot; Daniel Scotson; Christian Semmler; Serge Selezneff; Sophie Senani de Monredon; Kentaro Shinoda; Pawel Sokolowski; Uwe Schulz; Moussa Tembely; Filofteia Laura Toma; Pascal Tristant; Thibaut Van Hoof; Armelle Vardelle; Robert Vassen; Scott Wilson; Ping Xiao; Guan Jun Yang; Shuo Yin; Stephen Yue; Tianqi Zhu

doi:10.1007/s11666-026-02276-5

Innovative Coatings for a Greener Sky: The 2026 Strategic Roadmap for Thermal Spray and PVD Coatings

Andrew Ang
, Thibaut Archer
, Farzam Arhami
, Mettupalayam Balachander
, Kantesh Balani
, Dominique Billières
, Ann Bolcavage
, Giovanni Bolelli
, Marjorie Cavarroc-Weimer
, Sophie Costil
, Nicholas Curry
, Alain Denoirjean
, Ali Dolatabadi
, Alice Dolmaire
, William Duarte
, David Dublanche
, Julien Escobar
, Alice Fabre
, Gaël Fick
, Guillaume Fradet

Frank Gärtner, Edward J. Gildersleeve, Mohit Gupta, Jonathan Gutleber, Makoto Hasegawa, Bryan J. Harder, Brian Hazel, Hendrik Heinemann, Xianghui Hou, Tanvir Hussain, Eric Irissou, Mehdi Jadidi, Cédric Jaoul, Maria Ophelia Jarligo, Bertrand Jodoin, Shrikant Joshi, Andreas Killinger, Jolanta E. Klemberg-Sapieha, Komal Laul, Chang Jiu Li, André C. Liberati, Rocco Lupoi, Gilles Mariaux, Ludvik Martinu, André McDonald, Christian Moreau, Majid Nabavi, Aleksandra Nastic, Ahmet Hilmi Paksoy, Cédric Poupon, Vincent Rat, Óscar Rojas, Céline Ruelle, Pierre Sallot, Daniel Scotson, Christian Semmler, Serge Selezneff, Sophie Senani de Monredon, Kentaro Shinoda, Pawel Sokolowski, Uwe Schulz, Moussa Tembely, Filofteia Laura Toma, Pascal Tristant, Thibaut Van Hoof, Armelle Vardelle, Robert Vassen, Scott Wilson, Ping Xiao, Guan Jun Yang, Shuo Yin, Stephen Yue, Tianqi Zhu

School of Materials Sience and Engineering

Swinburne University of Technology
Université Paris-Saclay
Concordia University
Delta Air Lines
Indian Institute of Technology Kanpur
Saint-Gobain S.A.
Rolls-Royce
University of Modena and Reggio Emilia
Snecma Groupe SAFRAN
Université de technologie de Belfort Montbéliard
Thermal Spray Innovations
Université de Limoges
University of Toronto
Bodycote Surface Technology
IRT Saint Exupéry
Airbus Group
IRT M2P
Safran Aircraft Engines
Helmut-Schmidt-University
General Electric
University West
Oerlikon Metco Inc.
Yokohama National University
NASA Glenn Research Center
United Technologies Corporation
RWTH Aachen University
University of Nottingham
National Research Council of Canada
University of Alberta
University of Ottawa
University of Stuttgart
Ecole Polytechnique de Montreal
Xi'an Jiaotong University
Trinity College Dublin
Oerlikon Metco AG, Wohlen
University of Manchester
Centre de Transfert de Technologies Céramiques (CTTC)
National Institute of Advanced Industrial Science and Technology
Wrocław University of Science and Technology
German Aerospace Center
Fraunhofer Institute for Material and Beam Technology
Cenaero ASBL
Jülich Research Centre
McGill University

Research output: Contribution to journal › Comment/debate

Abstract

Decarbonizing aviation aims to reduce greenhouse gas emissions from aircraft operations, paving the way for sustainable air travel. This endeavor requires adopting advanced technologies, alternative fuels, high-performance coatings and efficient engineering solutions that minimize environmental impact while maintaining performance and safety standards. Two of the most prevalent and cost-effective methods for applying protective and functional coatings to aerospace components are thermal spray and physical vapor deposition. These techniques enhance the durability and efficiency of several components, resulting in fuel savings and an extended service life across the aviation industry. This supports the broader aim of transitioning the aviation industry to net-zero emissions and sustainable growth. This roadmap explores how these two coating techniques can promote sustainable aviation and identifies the challenges and opportunities in the aerospace sector for researchers and manufacturers of thermal spray and physical vapor deposition (PVD) coatings. It also proposes research directions to address these challenges and discusses the role of AI, which is crucial for breakthrough technologies in process optimization and integration, new coating development and coating design optimization. The roadmap is organized into 20 concise subsections, each focusing on a specific topic. Renowned specialists in each area were invited to summarize the current status of their field, discuss the challenges it faces, and offer recommendations for necessary research and development to overcome these issues. Together, these contributions vividly highlight the essential elements of the field and the challenges that lie ahead. The innovative ideas and concepts outlined in the roadmap reveal that the future path is both expansive and far-reaching.

Original language	English
Pages (from-to)	2099-2200
Number of pages	102
Journal	Journal of Thermal Spray Technology
Volume	35
Issue number	6
DOIs	https://doi.org/10.1007/s11666-026-02276-5
State	Published - Aug 2026

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

SDG 8 Decent Work and Economic Growth

Keywords

AI-driven modeling
abradable coatings
aerosol deposition
anti-icing coatings aeronautics
anti-oxidation coatings
chord plasma spray
cold spray
complex parts
environmental analysis
environmental barriers coatings
numerical twins
polymer substrate
refurbishment
substrate preparation
suspension plasma spray
thermal barrier coatings
thermal spray
vapor deposition
wear-resistant coatings

Access to Document

10.1007/s11666-026-02276-5

Cite this

Ang, A., Archer, T., Arhami, F., Balachander, M., Balani, K., Billières, D., Bolcavage, A., Bolelli, G., Cavarroc-Weimer, M., Costil, S., Curry, N., Denoirjean, A., Dolatabadi, A., Dolmaire, A., Duarte, W., Dublanche, D., Escobar, J., Fabre, A., Fick, G., ... Zhu, T. (2026). Innovative Coatings for a Greener Sky: The 2026 Strategic Roadmap for Thermal Spray and PVD Coatings. Journal of Thermal Spray Technology, 35(6), 2099-2200. https://doi.org/10.1007/s11666-026-02276-5

@article{c8183a2c6bac4cea891818ac55fa69f0,

title = "Innovative Coatings for a Greener Sky: The 2026 Strategic Roadmap for Thermal Spray and PVD Coatings",

abstract = "Decarbonizing aviation aims to reduce greenhouse gas emissions from aircraft operations, paving the way for sustainable air travel. This endeavor requires adopting advanced technologies, alternative fuels, high-performance coatings and efficient engineering solutions that minimize environmental impact while maintaining performance and safety standards. Two of the most prevalent and cost-effective methods for applying protective and functional coatings to aerospace components are thermal spray and physical vapor deposition. These techniques enhance the durability and efficiency of several components, resulting in fuel savings and an extended service life across the aviation industry. This supports the broader aim of transitioning the aviation industry to net-zero emissions and sustainable growth. This roadmap explores how these two coating techniques can promote sustainable aviation and identifies the challenges and opportunities in the aerospace sector for researchers and manufacturers of thermal spray and physical vapor deposition (PVD) coatings. It also proposes research directions to address these challenges and discusses the role of AI, which is crucial for breakthrough technologies in process optimization and integration, new coating development and coating design optimization. The roadmap is organized into 20 concise subsections, each focusing on a specific topic. Renowned specialists in each area were invited to summarize the current status of their field, discuss the challenges it faces, and offer recommendations for necessary research and development to overcome these issues. Together, these contributions vividly highlight the essential elements of the field and the challenges that lie ahead. The innovative ideas and concepts outlined in the roadmap reveal that the future path is both expansive and far-reaching.",

keywords = "AI-driven modeling, abradable coatings, aerosol deposition, anti-icing coatings aeronautics, anti-oxidation coatings, chord plasma spray, cold spray, complex parts, environmental analysis, environmental barriers coatings, numerical twins, polymer substrate, refurbishment, substrate preparation, suspension plasma spray, thermal barrier coatings, thermal spray, vapor deposition, wear-resistant coatings",

author = "Andrew Ang and Thibaut Archer and Farzam Arhami and Mettupalayam Balachander and Kantesh Balani and Dominique Billi{\`e}res and Ann Bolcavage and Giovanni Bolelli and Marjorie Cavarroc-Weimer and Sophie Costil and Nicholas Curry and Alain Denoirjean and Ali Dolatabadi and Alice Dolmaire and William Duarte and David Dublanche and Julien Escobar and Alice Fabre and Ga{\"e}l Fick and Guillaume Fradet and Frank G{\"a}rtner and Gildersleeve, \{Edward J.\} and Mohit Gupta and Jonathan Gutleber and Makoto Hasegawa and Harder, \{Bryan J.\} and Brian Hazel and Hendrik Heinemann and Xianghui Hou and Tanvir Hussain and Eric Irissou and Mehdi Jadidi and C{\'e}dric Jaoul and Jarligo, \{Maria Ophelia\} and Bertrand Jodoin and Shrikant Joshi and Andreas Killinger and Klemberg-Sapieha, \{Jolanta E.\} and Komal Laul and Li, \{Chang Jiu\} and Liberati, \{Andr{\'e} C.\} and Rocco Lupoi and Gilles Mariaux and Ludvik Martinu and Andr{\'e} McDonald and Christian Moreau and Majid Nabavi and Aleksandra Nastic and Paksoy, \{Ahmet Hilmi\} and C{\'e}dric Poupon and Vincent Rat and {\'O}scar Rojas and C{\'e}line Ruelle and Pierre Sallot and Daniel Scotson and Christian Semmler and Serge Selezneff and \{de Monredon\}, \{Sophie Senani\} and Kentaro Shinoda and Pawel Sokolowski and Uwe Schulz and Moussa Tembely and Toma, \{Filofteia Laura\} and Pascal Tristant and \{Van Hoof\}, Thibaut and Armelle Vardelle and Robert Vassen and Scott Wilson and Ping Xiao and Yang, \{Guan Jun\} and Shuo Yin and Stephen Yue and Tianqi Zhu",

note = "Publisher Copyright: {\textcopyright} The Author(s) 2026.",

year = "2026",

month = aug,

doi = "10.1007/s11666-026-02276-5",

language = "英语",

volume = "35",

pages = "2099--2200",

journal = "Journal of Thermal Spray Technology",

issn = "1059-9630",

publisher = "Springer New York",

number = "6",

}

Ang, A, Archer, T, Arhami, F, Balachander, M, Balani, K, Billières, D, Bolcavage, A, Bolelli, G, Cavarroc-Weimer, M, Costil, S, Curry, N, Denoirjean, A, Dolatabadi, A, Dolmaire, A, Duarte, W, Dublanche, D, Escobar, J, Fabre, A, Fick, G, Fradet, G, Gärtner, F, Gildersleeve, EJ, Gupta, M, Gutleber, J, Hasegawa, M, Harder, BJ, Hazel, B, Heinemann, H, Hou, X, Hussain, T, Irissou, E, Jadidi, M, Jaoul, C, Jarligo, MO, Jodoin, B, Joshi, S, Killinger, A, Klemberg-Sapieha, JE, Laul, K, Li, CJ, Liberati, AC, Lupoi, R, Mariaux, G, Martinu, L, McDonald, A, Moreau, C, Nabavi, M, Nastic, A, Paksoy, AH, Poupon, C, Rat, V, Rojas, Ó, Ruelle, C, Sallot, P, Scotson, D, Semmler, C, Selezneff, S, de Monredon, SS, Shinoda, K, Sokolowski, P, Schulz, U, Tembely, M, Toma, FL, Tristant, P, Van Hoof, T, Vardelle, A, Vassen, R, Wilson, S, Xiao, P, Yang, GJ, Yin, S, Yue, S & Zhu, T 2026, 'Innovative Coatings for a Greener Sky: The 2026 Strategic Roadmap for Thermal Spray and PVD Coatings', Journal of Thermal Spray Technology, vol. 35, no. 6, pp. 2099-2200. https://doi.org/10.1007/s11666-026-02276-5

TY - JOUR

T1 - Innovative Coatings for a Greener Sky

T2 - The 2026 Strategic Roadmap for Thermal Spray and PVD Coatings

AU - Ang, Andrew

AU - Archer, Thibaut

AU - Arhami, Farzam

AU - Balachander, Mettupalayam

AU - Balani, Kantesh

AU - Billières, Dominique

AU - Bolcavage, Ann

AU - Bolelli, Giovanni

AU - Cavarroc-Weimer, Marjorie

AU - Costil, Sophie

AU - Curry, Nicholas

AU - Denoirjean, Alain

AU - Dolatabadi, Ali

AU - Dolmaire, Alice

AU - Duarte, William

AU - Dublanche, David

AU - Escobar, Julien

AU - Fabre, Alice

AU - Fick, Gaël

AU - Fradet, Guillaume

AU - Gärtner, Frank

AU - Gildersleeve, Edward J.

AU - Gupta, Mohit

AU - Gutleber, Jonathan

AU - Hasegawa, Makoto

AU - Harder, Bryan J.

AU - Hazel, Brian

AU - Heinemann, Hendrik

AU - Hou, Xianghui

AU - Hussain, Tanvir

AU - Irissou, Eric

AU - Jadidi, Mehdi

AU - Jaoul, Cédric

AU - Jarligo, Maria Ophelia

AU - Jodoin, Bertrand

AU - Joshi, Shrikant

AU - Killinger, Andreas

AU - Klemberg-Sapieha, Jolanta E.

AU - Laul, Komal

AU - Li, Chang Jiu

AU - Liberati, André C.

AU - Lupoi, Rocco

AU - Mariaux, Gilles

AU - Martinu, Ludvik

AU - McDonald, André

AU - Moreau, Christian

AU - Nabavi, Majid

AU - Nastic, Aleksandra

AU - Paksoy, Ahmet Hilmi

AU - Poupon, Cédric

AU - Rat, Vincent

AU - Rojas, Óscar

AU - Ruelle, Céline

AU - Sallot, Pierre

AU - Scotson, Daniel

AU - Semmler, Christian

AU - Selezneff, Serge

AU - de Monredon, Sophie Senani

AU - Shinoda, Kentaro

AU - Sokolowski, Pawel

AU - Schulz, Uwe

AU - Tembely, Moussa

AU - Toma, Filofteia Laura

AU - Tristant, Pascal

AU - Van Hoof, Thibaut

AU - Vardelle, Armelle

AU - Vassen, Robert

AU - Wilson, Scott

AU - Xiao, Ping

AU - Yang, Guan Jun

AU - Yin, Shuo

AU - Yue, Stephen

AU - Zhu, Tianqi

PY - 2026/8

Y1 - 2026/8

N2 - Decarbonizing aviation aims to reduce greenhouse gas emissions from aircraft operations, paving the way for sustainable air travel. This endeavor requires adopting advanced technologies, alternative fuels, high-performance coatings and efficient engineering solutions that minimize environmental impact while maintaining performance and safety standards. Two of the most prevalent and cost-effective methods for applying protective and functional coatings to aerospace components are thermal spray and physical vapor deposition. These techniques enhance the durability and efficiency of several components, resulting in fuel savings and an extended service life across the aviation industry. This supports the broader aim of transitioning the aviation industry to net-zero emissions and sustainable growth. This roadmap explores how these two coating techniques can promote sustainable aviation and identifies the challenges and opportunities in the aerospace sector for researchers and manufacturers of thermal spray and physical vapor deposition (PVD) coatings. It also proposes research directions to address these challenges and discusses the role of AI, which is crucial for breakthrough technologies in process optimization and integration, new coating development and coating design optimization. The roadmap is organized into 20 concise subsections, each focusing on a specific topic. Renowned specialists in each area were invited to summarize the current status of their field, discuss the challenges it faces, and offer recommendations for necessary research and development to overcome these issues. Together, these contributions vividly highlight the essential elements of the field and the challenges that lie ahead. The innovative ideas and concepts outlined in the roadmap reveal that the future path is both expansive and far-reaching.

AB - Decarbonizing aviation aims to reduce greenhouse gas emissions from aircraft operations, paving the way for sustainable air travel. This endeavor requires adopting advanced technologies, alternative fuels, high-performance coatings and efficient engineering solutions that minimize environmental impact while maintaining performance and safety standards. Two of the most prevalent and cost-effective methods for applying protective and functional coatings to aerospace components are thermal spray and physical vapor deposition. These techniques enhance the durability and efficiency of several components, resulting in fuel savings and an extended service life across the aviation industry. This supports the broader aim of transitioning the aviation industry to net-zero emissions and sustainable growth. This roadmap explores how these two coating techniques can promote sustainable aviation and identifies the challenges and opportunities in the aerospace sector for researchers and manufacturers of thermal spray and physical vapor deposition (PVD) coatings. It also proposes research directions to address these challenges and discusses the role of AI, which is crucial for breakthrough technologies in process optimization and integration, new coating development and coating design optimization. The roadmap is organized into 20 concise subsections, each focusing on a specific topic. Renowned specialists in each area were invited to summarize the current status of their field, discuss the challenges it faces, and offer recommendations for necessary research and development to overcome these issues. Together, these contributions vividly highlight the essential elements of the field and the challenges that lie ahead. The innovative ideas and concepts outlined in the roadmap reveal that the future path is both expansive and far-reaching.

KW - AI-driven modeling

KW - abradable coatings

KW - aerosol deposition

KW - anti-icing coatings aeronautics

KW - anti-oxidation coatings

KW - chord plasma spray

KW - cold spray

KW - complex parts

KW - environmental analysis

KW - environmental barriers coatings

KW - numerical twins

KW - polymer substrate

KW - refurbishment

KW - substrate preparation

KW - suspension plasma spray

KW - thermal barrier coatings

KW - thermal spray

KW - vapor deposition

KW - wear-resistant coatings

UR - https://www.scopus.com/pages/publications/105046219392

U2 - 10.1007/s11666-026-02276-5

DO - 10.1007/s11666-026-02276-5

M3 - 评论/辩论

AN - SCOPUS:105046219392

SN - 1059-9630

VL - 35

SP - 2099

EP - 2200

JO - Journal of Thermal Spray Technology

JF - Journal of Thermal Spray Technology

IS - 6

ER -

Innovative Coatings for a Greener Sky: The 2026 Strategic Roadmap for Thermal Spray and PVD Coatings

Abstract

UN SDGs

Keywords

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