Thermal spray coatings have the advantage of providing thick and functional coatings from a range of engineering materials. The associated coating processes provide good control of coating thickness, morphology, microstructure, pore size and porosity, and residual strain in the coatings through selection of suitable process parameters for any coating material of interest. This review consolidates scarce literature on thermally sprayed components which are critical and vital constituents (e. g., catalysts (anode/cathode), solid electrolyte, and transport layer, including corrosion‐prone parts such as bipolar plates) of the water splitting electrolysis process for hydrogen production. The research shows that there is a gap in thermally sprayed feedstock material selection strategy as well as in addressing modelling needs that can be crucial to advancing applications exploiting their catalytic and corrosion‐resistant properties to split water for hydrogen production. Due to readily scalable production enabled by thermal spray techniques, this manufacturing route bears potential to dominate the sustainable electrolyser technologies in the future. While the well‐established thermal spray coating variants may have certain limitations in the manner they are currently practiced, deployment of both conventional and novel thermal spray approaches (suspension, solution, hybrid) is clearly promising for targeted development of electrolysers.

Vibrations of slender structures associated with the external flow present a design challenge for the energy production systems placed in the marine environment. The current study explores the accuracy of the semi-empirical wake oscillator models for vortex-induced vibrations (VIV) based on the optimization of (a) the damping term and (b) empirical coefficients in the fluid equation. This work investigates the effect of ten fluid damping variations, from the classic van der Pol to more sophisticated fifth-order terms, and prediction of the simplified case of the VIV of transversally oscillating rigid structures provides an opportunity for an extended, comprehensive comparison of the performance of tuned models. A constrained nonlinear minimization algorithm in MATLAB is applied to calibrate considered models using the published experimental data, and the weighted objective function is formulated for three different mass ratios. Comparison with several sources of published experimental data for cross-flow oscillations confirms the model accuracy in the mass ratio range. The study indicates the advantageous performance of the models tuned with the medium mass ratio data and highlights some advantages of the Krenk–Nielsen wake oscillator.

The estimates of hydrodynamic forces for a group of structures represent a challenge for the design of offshore systems, as they are subject to changes with a variation in flow profiles. The fluctuating effects may be more pronounced or, on the contrary, suppressed if the cross-sectional shape of structures in an array is altered. The present work performs a series of 2D numerical simulations for the flow past six identical stationary cylinders of three distinct geometrical shapes arranged in a 2 × 3 matrix configuration. The flow profiles considered have an averaged velocity corresponding to the critical flow regime of a Reynolds number of 2.5 × 10⁵. The detached eddy simulation k–ω SST turbulence model is employed to perform a comprehensive investigation of the fluid force coefficients, their frequencies and vortex formation patterns. The effect of the spacing ratio varied simultaneously among the structures from 2 to 7 is considered in conjunction with the change in the flow profile and the cylinders’ cross-section. The results of simulations show a higher mean drag on the upstream cylinders, reduced mean drag on the mid- and downstream cylinders with the second cross-sectional shape, and a higher mean drag on the cylinders with the third cross-sectional shape, compared to the original circular cylinders.

This paper considers a system with two offshore structures in tandem, where the upstream square structure is fixed and the downstream circular structure has one degree of freedom. Cylinders are subject to uniform and linearly sheared flow conditions. The dynamics of the downstream structure are investigated by using a computational fluid dynamics approach for a Reynolds number range of 1000–6500 at the centerline. The spacing ratio for the tandem structures is L/D = 6 in this work, corresponding to the wake interference regime. The effect of the shear parameter on the development of vortex-induced vibrations in the lock-in state within the downstream structure is studied, in comparison with the lock-in of an isolated circular structure. The results of this research include statistics on the displacement amplitude, drag and lift coefficients, frequency ratio, time histories and contours of vorticity. The results obtained show the maximum displacement amplitude of the isolated structure in a uniform flow at the level of 0.8 diameters during the upper branch. The investigation also shows a later development in the maximum displacement during the upper branch of the downstream structure under shear flow conditions, with the highest maximum displacement of 1.18 diameters seen for the shear parameter of 0.05.

This paper presents a numerical investigation into the vortex-induced vibrations (VIV) of a smooth and a marine-fouled circular cylinder with two degrees of freedom (2DOF), subjected to a turbulent oscillatory flow. The study aims to elucidate the critical influence of the Keulegan-Carpenter (KC) number of 5, 10, and 15 on the vibration response, lock-in regime, frequency synchronization, trajectory patterns and vorticity. Simulations are performed by solving the two-dimensional unsteady Reynolds-Averaged Navier–Stokes (RANS) equations with the Shear Stress Transport (SST) k-ω turbulence model in ANSYS Fluent 2025 R1. An increase in the KC number leads to a significant broadening of the lock-in region, an increase in maximum vibration amplitudes and their emergence at higher reduced velocities. Another key finding is the consistent suppressive effect of biofouling on cross-flow vibrations. The biofouled cylinder exhibits lower cross-flow amplitudes across all KC numbers compared to the smooth cylinder, almost plateauing at around 1.0D for KC = 10 and 15, while the smooth cylinder reaches amplitudes of up to 1.8D and a maximum in-line amplitude of 4.46D. These findings have critical implications for the realistic fatigue life assessment and design of offshore marine structures, highlighting the necessity of incorporating surface roughness effects into VIV prediction models.