Influence of Powders on Thermal Spray Coating Structures: Recent Developments in Nano or Finely Structured Coatings and Some Safety Issues

This paper reviews various powder treatments and particle alteration processes and evaluates their effect on the microstructure and properties of thermal spray coatings. It discusses the benefits and drawbacks of thermal plasma treatments for powders, the use of self-propagating high-temperature synthesis (SHS), and different ways nanopowders are produced and sprayed. It covers several spraying methods and a wide range of materials, including ceramics, metals and alloys, cermets, and composites. It also covers mechanical alloying and powder milling processes and addresses the potential risks of inhaling nanopowders.