{"status":"ok","message-type":"work","message-version":"1.0.0","message":{"indexed":{"date-parts":[[2026,7,27]],"date-time":"2026-07-27T06:02:47Z","timestamp":1785132167036,"version":"3.55.0"},"reference-count":163,"publisher":"MDPI AG","issue":"15","license":[{"start":{"date-parts":[[2026,7,24]],"date-time":"2026-07-24T00:00:00Z","timestamp":1784851200000},"content-version":"vor","delay-in-days":0,"URL":"https:\/\/creativecommons.org\/licenses\/by\/4.0\/"}],"content-domain":{"domain":[],"crossmark-restriction":false},"short-container-title":["Materials"],"abstract":"<jats:p>Thermal spray coatings have also been adopted as a solution strategy to increase the service life and improve the performance of designed engineered electrochemical energy devices, especially batteries and solid oxide cells. These systems share common attributes of challenges in interfacial stability, degradation in microstructure, and transport limitations in extreme operating conditions. This review revolves around the significance of microstructural coating, that is, distribution of porosity, phase composition, splat bonding, and interface quality in regulating the electrochemical performance. High-entropy alloys, functional graded material, and nanostructured feedstock are also mentioned in the context of how they can be utilized to modify coating properties and make the device more reliable. The processing environments and microstructure development relative to major performance indices, such as ionic\/ electronic conductivity, corrosion behavior, and stability, are critically examined. Furthermore, the trade-off between the energy consumed during the synthesis of the powders and the efficiency of deposition of the coating is discussed to give information on sustainable production. Other new approaches involving the use of computational models and artificial intelligence to maximize the processes are also discussed in this review. Generally, this paper creates a process\u2013structure\u2013performance system for the rational development of thermal spray coatings in the next generation of electrochemical-based energy systems.<\/jats:p>","DOI":"10.3390\/ma19153175","type":"journal-article","created":{"date-parts":[[2026,7,27]],"date-time":"2026-07-27T05:49:27Z","timestamp":1785131367000},"page":"3175","update-policy":"https:\/\/doi.org\/10.3390\/mdpi_crossmark_policy","source":"Crossref","is-referenced-by-count":0,"title":["Enhancing Durability and Efficiency of Electrochemical Energy Devices (Batteries and Solid Oxide Cells) Through Thermal Spray Coating Technologies: A Review"],"prefix":"10.3390","volume":"19","author":[{"ORCID":"https:\/\/orcid.org\/0000-0002-8760-5322","authenticated-orcid":false,"given":"Amrinder","family":"Mehta","sequence":"first","affiliation":[{"name":"Research and Development Cell, Lovely Professional University, Phagwara 144411, Punjab, India"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-1668-8765","authenticated-orcid":false,"given":"Hitesh","family":"Vasudev","sequence":"additional","affiliation":[{"name":"Research and Development Cell, Lovely Professional University, Phagwara 144411, Punjab, India"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0003-1784-2610","authenticated-orcid":false,"given":"Brijesh","family":"Prasad","sequence":"additional","affiliation":[{"name":"Department of Mechanical Engineering, Graphic Era (Deemed to be University), Dehradun 248005, Uttarakhand, India"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Suresh","family":"Singh","sequence":"additional","affiliation":[{"name":"Centre for Research Impact and Outcome, Chitkara University Institute of Engineering and Technology, Chitkara University, Punjab, Rajpura 140401, Punjab, India"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0003-2815-8443","authenticated-orcid":false,"given":"Manoj","family":"Kumar","sequence":"additional","affiliation":[{"name":"Department of Mechanical Engineering, ABES Engineering College, Ghaziabad 201009, Uttar Pradesh, India"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Sachin","family":"Sirohi","sequence":"additional","affiliation":[{"name":"Department of Mechanical Engineering, SRM Institute of Science and Technology, Delhi NCR Campus, Modinagar 201204, Uttar Pradesh, India"}],"role":[{"vocabulary":"crossref","role":"author"}]}],"member":"1968","published-online":{"date-parts":[[2026,7,24]]},"reference":[{"key":"ref_1","doi-asserted-by":"crossref","first-page":"1700395","DOI":"10.1002\/smtd.201700395","article-title":"In situ\/operando characterization techniques to probe the electrochemical reactions for energy conversion","volume":"2","author":"Li","year":"2018","journal-title":"Small Methods"},{"key":"ref_2","doi-asserted-by":"crossref","first-page":"30","DOI":"10.1007\/s43979-024-00105-8","article-title":"Large-scale energy storage for carbon neutrality: Thermal energy storage for electrical vehicles","volume":"3","author":"Zhao","year":"2024","journal-title":"Carbon Neutrality"},{"key":"ref_3","doi-asserted-by":"crossref","first-page":"2440","DOI":"10.1016\/j.rser.2017.09.003","article-title":"Current status of water electrolysis for energy storage, grid balancing and sector coupling via power-to-gas and power-to-liquids: A review","volume":"82","author":"Buttler","year":"2018","journal-title":"Renew. 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