Significant expansion of thermal spray technology occurred with the invention of plasma spray, detonation gun, and high-velocity oxyfuel (HVOF) deposition technologies. This article provides a brief history of the major initiating inventions/developments of thermal spray processes. It provides information on feedstock materials developed for specific thermal spray processes.

Coatings and other surface modifications are used for a variety of functional, economic, and aesthetic purposes. Two major applications of thermal spray coatings are for wear resistance and corrosion resistance. This article discusses thermal (surface hardening) and thermochemical (carburizing, nitriding, and boriding) surface modifications, electrochemical treatments (electroplating, and anodizing), chemical treatments (electroless plating, phosphating, and hot dip coating), hardfacing, and thermal spray processes. It provides information on chemical and physical vapor deposition techniques such as conventional CVD, laser-assisted CVD, cathodic arc deposition, molecular beam epitaxy, ion plating, and sputtering.

This article is a brief guide to information sources on thermal spray technology. The sources provided by ASM International and the Thermal Spray Society (TSS) include magazines and journals as well as reference books, including the ASM Handbook series, conference proceedings, newsletters, education courses, and videos. The article provides information on the specifications, standards, and quality control for coatings.

Thermal spray is a generic term for a group of coating processes used to apply metallic, ceramic, cermet, and some polymeric coatings for a broad range of applications. This article provides a brief description of commercially important thermal spray processes, namely, powder-fed flame spray, wire- or rod-fed flame spray, electric arc spray, plasma arc spray, vacuum plasma spray, high-velocity oxyfuel spray, detonation gun deposition, and cold spray, and their advantages. It provides details on the microstructural characteristics of thermal spray coatings. The article also presents information on a wide variety of materials that can be thermal sprayed, such as metals, ceramics, intermetallics, composites, cermets, polymers, and functionally gradient materials. Tables are included, which list the thermal spray processes and coating properties of importance for various industrial applications.