Hybrid plasma spraying is emerging as the next potential technology leap in thermal spraying. The combination of high throughput and deposition rates of coatings sprayed from powders with the tailored functionality of liquid-feedstock sprayed coatings appears highly promising for a wide range of applications. Moreover; possible refined mixtures of different materials come readily with the utilization of multiple feedstocks with varying particle sizes. However; the practical aspects of hybrid coatings production are accompanied with several peculiarities not encountered when using distinct feedstocks. To deepen the understanding of this novel route; this paper presents fundamental hybrid coating formation principles and the effect of selected deposition parameters using multiple case-study material systems; such as Al2O3-YSZ; Al2O3-Cr2O3; and Al2O3-TiO2.

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