Titanium boron composite coatings with superior wear performance were selected for use in materials experiments on the International Space Station. The titanium-boron nitride composite coatings were prepared using an atmospheric plasma spray technique from engineered composite powders. The coatings were subjected to extensive characterization and tribological studies. The results show tremendous improvement in the wear performance.

Vacuum plasma and low pressure plasma spray technologies each provide unique solutions for achieving superior properties in metallic coatings that require low oxide content and high density. Applications include various turbine engine components, as well as biomedical and electronics components.

Heat shields help protect vehicle-critical components that could delaminate and fail if exposed to high temperatures for any length of time. This article describes a solution that features ceramic platelets applied via plasma spray onto a metal substrate to create a heat shield that adds additional temperature resistance in comparison to standard pressed aluminum versions.

New thermal and cold spray technologies are being developed to extend the lifespan of thermal barrier coating (TBC) systems at elevated temperatures. This article describes the relevant attributes of coating technologies such as high velocity air fuel, high velocity air plasma spray, and high pressure cold spray for use in TBC systems.

Innovations built into a new plasma spray torch address shortcomings of previous axial injection equipment.

Identifying metallographic TSC artifacts, specifically in air plasma spray zirconia-based thermal barrier coatings.

New thermal spray methods optimized for the production of functional coatings are bridging the gap between traditional thermal spraying and thin-film deposition technologies. Two such methods, one known alternately as very low pressure plasma spraying (VLPPS) or plasma spray-physical vapor deposition (PS-PVD) and one called thin-film thermal spray chemical vapor deposition (CVD), are briefly reviewed here.

This article describes work being done at the University of Limoges to develop thermal spray coatings for use in new nuclear power plant designs.

What needs to be discovered, learned, and understood to advance thermal spray beyond existing practices? Is revenue a realistic indicator of progress and advancement or is it just a framework for a much bigger picture? This article reviews some past successes, failures, and unrealized potentials of industrial and manufacturing outcomes and provides details of the knowns and unknowns of the thermal spray portfolio.

Thermal spray technology is increasingly being used in alternative energy applications such as solid-oxide fuel cells, solar panels, and wind and hydropower turbines.

Zircotec Ltd., UK, originally developed its technologies for use in nuclear reactors. During the last decade, its coatings have been used in several other applications, including orthopedic implants, and the company has expanded into the defense sector with a greater emphasis on heat protection. This Technical Spotlight outlines some of the company's process capabilities.

One of the most recent success stories for thermal spray in the automotive industry involves the development of plasma transferred wire arc (PTWA) for aluminum engine blocks. Driven by the demand to increase fuel efficiency, automakers are placing emphasis on decreasing overall vehicle weight as well as improving engine efficiency by reducing internal friction losses. The surface structure of the composite coating created by the PTWA process promotes favorable lubrication, low friction, wear resistance, improved heat transfer, and decreased bore distortion in engine block cylinders.

This case study reviews the considerations in applying plasma spray thermal barrier coatings on augmenters used in military aircraft turbine engines to extend their service life.

Thermal barrier coatings (TBCs) with segmented or cracked microstructures exhibit enhanced thermal cyclic behavior and erosion resistance, along with improved application economics, over conventional TBCs.

This article explains how coating technology originally developed for use in nuclear power generating equipment is helping automotive engineers solve heat, wear, and performance challenges using new materials and design approaches.

This article provides a brief overview of the applications of multimodal alumina-titania (n-AT) coatings stemming from a five-year program on thermal spray nanocoatings sponsored by the U.S. Office of Naval Research (ONR). In the main example, plasma sprayed n-AT coatings are applied to the propulsion shafts of Mine Countermeasure ships, bringing a fourfold increase in service life.

Stony Brook celebrates a milestone by reflecting on its Center for Thermal Spray Research from the early years of growth and expansion to the development of an industrial consortium.

The use of coatings to enhance the performance of components is one of the most powerful tools in materials engineering. This article highlights some examples of how thermal spray technologies are used to enhance surface properties for selected applications and industries.

This article presents a brief overview of thermally sprayed thermal barrier coatings (TBCs) used in gas turbines that generate electrical power.

Thermal spray plays an important but latent role in many energy generation applications. Strong R&D commitment is required to further expand its technological envelope. This article addresses future directions in the use of thermal spray coating technologies in the energy sector.