Functional Materials and Multilayers by Thermal Spray: Opportunities and Challenges

Thermal spray (TS) continues to enjoy unprecedented growth as an innovative and multi-platform deposition technology. TS coatings are now critical to various engineering systems and industry recognizing its versatility and economics, have introduced it into manufacturing. The majority of modern TS  applications are  deemed ‘‘passive’’ as their primary role is to protect the underlying substrate from the operating environment.  However,  TS has long been considered a thick film functional materials technology with capabilities to perform, electrical, electronic, sensory functions.  There is renewed industrial interest to take advantage of TS capability to rapidly consolidate dissimilar materials at relatively low temperatures for thick film applications.   However, the complexity of understanding/controlling materials functions especially those resulting from rapid solidification and layered assemblage has stymied expansion into the area of functional materials. That situation is changing: not withstanding renewed industrial interest much progress has been achieved in fundamental understanding as well as application possibilities.  In This presentation will critically examine the past, present and future in terms of both technological capabilities as well as application interests.