Thermally sprayed diffusion barrier coatings on C/C light-weight charging racks for furnace applications

► Ceramic coatings were applied on carbon fiber-reinforced carbon by thermal spraying. ► Extensive laboratory-scaled and industrial-practice thermocyclic tests were conducted. ► APS-sprayed Al2O3 and Al2O3/Cr2O3 on C/C-SiC showed the best thermomechanic behavior. ► The APS coatings exhibited superior wear resistance compared to conventional paints. ► Results offer an energy-saving opportunity to replace steel charging racks.