Abstract The "Shock Stabilized Supersonic Spray System" is currently designed for operation at oxygen supply pressures of 250 psig or 500 psig. It sprays both powder and wire. Low heat losses result in flame-jet temperatures appreciably higher than for chamber type geometries. Increased spray rates and deposit efficiencies result. Simultaneous powder and wire spraying can lead to zero coating stress allowing unlimited thickness build-up. Post flame quenching during wire spraying reduces liquid droplet temperatures nearly eliminating "splashing", while keeping the substrate cool.