Thermal spray is a continuous melt-spray process, in which particles (e.g., 1-50µm dia.) of virtually any material are melted and accelerated to high velocities, through either a combustion flame or a DC or RF thermal plasma arc. The droplets impinge on a substrate and rapidly solidify to form a thin "splat". The splats accumulate into a well- bonded deposit, generally >10µm thick. The resulting microstructure and, thus, properties, rely critically on the processing parameters, which are numerous and complex.

In applications of thermal spray there is a need to develop a robust, reliable and reproducible processing technology based on science. Physics-based process models, design tools and control strategies are vital for the efficient utilization of the process. Although there are notable research activities in varied aspects of the technology, these have been largely conducted independently. The Center for Thermal Spray Research (CTSR) has established an interdisciplinary team bringing a concerted, focused effort to the subject in order to elevate the fundamental understanding of the process and its relation to microstructural characteristics of the deposits and, thus, to their properties. New opportunities have emerged, where the flexibility and cost-effectiveness of thermal spray will play a role in revolutionizing manufacturing methods for a range of surface engineered systems.

Because materials science is at the core of the understanding of these complex coatings, an interdisciplinary consortium centered at SUNY-Stony Brook was formed as an National Science Foundation Materials Research Science and Engineering Center (MRSEC) in 1996 to achieve insight into thermal spray process synthesis and coatings properties. CTSR has established liaisons among US and foreign universities, national laboratories and industry, allowing fresh research thrusts and enhanced graduate and undergraduate training. CTSR's science-based interests extend to rapid solidification; accessing regions of phase diagrams not readily available using other means; processing/properties of metastable phases; synthesizing materials having novel electrical/magnetic properties; mechanics and micro-mechanical deformation of graded materials; damage tolerance and reliability of coatings; developing and applying a wide range of materials analysis techniques. These broadly integrated efforts offer expansive opportunities, suggesting fertile areas of materials research. That CTSR introduced new, successful initiatives is attested to by the productivity of our research coalitions, resulting in numerous publications, patents and significant related and complementary programs, derived from industrial and other support. These achievements have had, and are anticipated to continue to have, a substantial impact on materials science and on the technology of thermal spray.