Polyurethane Nanocomposite Coatings for Anti‐Erosion Applications: Fundamental Aspects and Latest Advancements

ABSTRACT

Erosion is a major degradation mechanism affecting components exposed to solid particle impingement, cavitation, slurry flow, rain impact, wind‐blown sand, and fluid turbulence. Industries including aerospace, marine, offshore oil and gas, wind energy, transportation, and power generation experience significant economic losses due to erosion‐induced material damage. Polyurethane (PU) coatings have emerged as attractive anti‐erosion materials because of their elasticity, toughness, adhesion, and impact resistance. However, conventional PU coatings often exhibit insufficient long‐term durability under severe erosive conditions. Recent advances in nanotechnology have enabled the development of PU nanocomposite coatings incorporating silica, graphene, graphene oxide (GO), carbon nanotubes (CNTs), nanoclays, MXenes, metal oxides, and hybrid nanoparticles to enhance erosion resistance. These nanoparticles improve energy dissipation, crack deflection, hardness, interfacial adhesion, and barrier performance. Recent studies further demonstrate multifunctional anti‐erosion coatings combining corrosion protection, self‐healing capability, de‐icing performance, and environmental resistance. This review summarizes the latest developments in nanoparticle‐containing PU coatings for anti‐erosion applications, emphasizing nanoparticle selection, fabrication methods, erosion mechanisms, performance enhancement strategies, industrial applications, challenges, and future research directions. Recent advances suggest that graphene‐based nanofillers, MXenes, functionalized silica nanoparticles, and hybrid nanostructures will play key roles in next‐generation anti‐erosion PU coatings.