Graphene-based coating systems have emerged as a new generation of flame-retardant materials with outstanding thermal stability, mechanical robustness, and multifunctionality. This review provides a comprehensive analysis of the thermal behavior, degradation pathways, and flame-retardant performance of graphene-enhanced nanocomposite coatings. The discussion begins with fundamental flame-retardant mechanisms—char formation, heat dissipation, and radical trapping—highlighting how graphene facilitates the development of compact, thermally stable carbonized layers that act as effective barriers to heat and oxygen. The synergistic interactions between graphene and conventional flame retardants, including phosphorus-, nitrogen-, and metal oxide-based additives, are critically examined to explain their dual-phase (gas and condensed) protective actions. Advanced coating architectures—polymeric (epoxy, polyurethane, and polyaniline), metal oxide/graphene, ceramic/graphene, and MXene–graphene hybrids—are reviewed with emphasis on fire resistance, smoke suppression, and thermal endurance. These hybrid systems exhibit significant reductions in peak heat release rate (20–40%) and increases in char yield (15–30%) compared with pristine polymers. Next-generation fabrication methods—ranging from layer-by-layer assembly and plasma-assisted deposition to 3D printing, electrospinning, and spray coating—are paving the way for scalable, uniform, and high-performance flame-retardant coatings. Additionally, smart graphene-based coatings capable of self-healing, real-time fire detection and multifunctional properties—such as electromagnetic shielding and corrosion protection—are discussed. Finally, a comparative analysis with conventional flame-retardant coatings underscores the superior stability, environmental compatibility, and long-term durability of graphene-based systems. The review concludes with future perspectives on green synthesis, multicomponent hybridization, and intelligent monitoring integration for next-generation fire-safe materials in aerospace, automotive, and electronic applications.
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