Erosion caused by the repeated impact of particles on the surface of a substance is a common wear method resulting in the gradual and continual loss of affected objects. It is a crucial problem in several modern industries because the surfaces of various products and materials are frequently subjected to destructively erosive situations. Polymers and their hybrid materials are suitable, in powdered form, for use as coatings in several different applications. This review paper aims to provide extensive information on the erosion behaviors of thermoset and thermoplastic neat resin and their hybrid material composites. Specific attention is paid to the influence of the properties of selected materials and to impingement parameters such as the incident angle of the erodent, the impact velocity of the erodent, the nature of the erodent, and the erosion mechanism. The review further extends the information available about the erosion techniques and numerical simulation methods used for wear studies of surfaces. An investigation was carried out to allow researchers to explore the available selection of materials and methods in terms of the conditions and parameters necessary to meet current and future needs and challenges, in technologically advanced industries, relating to the protection of surfaces. During the review, which was conducted on the findings in the literature of the past fifty years, it was noted that the thermoplastic nature of composites is a key component in determining their anti-wear properties; moreover, composites with lower glass transition, higher ductility, and greater crystallinity provide better protection against erosion in advanced surface applications.

---

Erosion by solid particles results in the thinning of components, surface crumpling, abrading, roughening, scratching, deprivation, and a drop in the practical lifespan of the affected components. Hence, wear resulting from particle impact has been deemed a critical challenge; it is responsible for many breakdowns, collapses, and failures in engineering applications. A robust struggle is ongoing to develop coatings that impede the activity of metal erosion, which is estimated to cost U.S. industries more than two hundred billion dollars yearly [32,33]. A summary of the historical utilization of different materials for this purpose is presented in Figure 3. Earlier understandings of the erosion process proposed that materials with greater hardness, for example, metal and ceramic-based materials, could deliver exceptional wear resistance. As such, conventionally, single-phase coatings of pure metals, metal nitrides, metal carbides, and alloys have been employed [34,35,36]. However, these coatings were lacking in terms of erosion-resistant performance and did not perform well for normal angles due to their high internal stress. In addition, upon impact with sand particles, some metals may spark [24].

---

Industrial Challenges:Erosion presents significant challenges across various industries, such as oil and gas, aviation, and power generation. It leads to surface degradation, failure, and accidents, compromising safety and operational efficiency.

Maintenance Costs: Erosion results in high maintenance costs due to frequent repairs and replacements. Unplanned stoppages for maintenance further escalate operational costs

Productivity and Efficiency: Degradation of surfaces reduces the productive service life and efficiency of industrial components, impacting overall productivity and revenue.

Improved Material Selection: Research helps in understanding the interaction of surfaces with erosive agents, guiding the selection of materials with optimal wear resistance for specific industrial applications.

Development of Advanced Materials:The study of erosion mechanisms and factors influencing erosion leads to the development of advanced materials and coatings that exhibit superior erosion resistance, enhancing component durability and performance.

Cost Reduction:By reducing the frequency and severity of erosion, research contributes to lowering maintenance costs and minimizing unplanned downtime, leading to cost savings.

---

Very few comprehensive investigations have used polymers and their hybrid composites for erosion-resistant applications. The data given in Table 1 show that although a detailed study was carried out using thermoset and thermoplastic polymers, some parameters, such as wear coefficient, are still unexamined. Although researchers have reported on composites in thermal, mechanical, and morphological studies relating to the wear of surfaces, gaps are nevertheless observed when calculating the erosion rates. Some of the composites' reported properties can be related to erosion, as seen in Table 3. Given that there are some common governing parameters for erosion and other applications, the reported materials that have properties related to erosion can also be assessed for wear applications. Only composites using fillers such as glass fibers and carbon fibers have been extensively reported on with respect to erosion variables, as seen in Table 2. However, there is very little research available on estimations of the erosive wear of materials using nanofillers. Moreover, in many research papers, the data presented are derived using only simulation software, and no experimental results are used to verify them. As there are many controlling factors for erosion, in the majority of cases, even if data are available for certain composite materials, the calculated parameters differ for other composites of interest; therefore, there is still a need to explore more in this field and to obtain harmonized and adequate data. In particular, in this area of study, new combinations of materials should be explored.

Increasing Industrialization:As industries expand, the wear and tear on machinery and infrastructure increase, leading to greater demand for erosion-resistant materials and coatings.

Technological Advancements:Innovations in materials science, particularly in nanocomposites and advanced coatings, are creating new opportunities for more effective erosion control solutions.

Regulatory and Safety Standards:Stricter regulations and safety standards in industries like oil and gas and aerospace necessitate the use of advanced materials and coatings to prevent erosion-related failures.

Oil and Gas: This industry is particularly affected by erosion due to the harsh conditions of drilling and extraction processes. Solutions for erosion control can significantly reduce maintenance costs and prevent catastrophic failures.

Manufacturing and Machinery:General manufacturing processes involve abrasive conditions that lead to erosion. Solutions here can enhance the lifespan and performance of machinery, reducing downtime and costs.