Advanced Surface Protection Strategies for Refurbished Hydropower Components: A Critical Review of Chemical and Manufacturing Approaches

This paper presents a critical review of surface protection strategies for refurbished hydropower components, with emphasis on the manufacturing and materials-processing logic that links damage mechanisms, substrate condition, deposition route, microstructure, and service performance. The literature indicates that cavitation erosion, sediment abrasion, corrosion, and their synergistic interactions are intensified by flexible and off-design hydropower operation, making refurbishment decisions increasingly surface-sensitive rather than purely bulk-material problems. Thermal spray and laser cladding remain the dominant industrially relevant routes, while cold spray and emerging multi-principal-element, high-entropy, and Fe-based amorphous systems expand the design space for lower heat input, better defect control, and improved cavitation resistance. Across the considered studies, the most consistent conclusion is that hardness alone is not a reliable selection criterion; porosity, interfacial integrity, crack susceptibility, residual stress, and the ability to accommodate local deformation govern real durability. Chemical pre-treatments, sealants, and hybrid finishing routes appear less mature as standalone hydropower solutions, but are important enablers for substrate activation, coating densification, and corrosion mitigation. Therefore, the review proposes a refurbishment-oriented framework in which route selection is based on the initial damage state of the component, the admissible thermal load on the substrate, the required build-up thickness, and the expected cavitation/slurry/corrosion regime.