Thermal sprayed ceramic coatings: fundamental issues and application considerations

This paper reviews progress in science and applications of thermal sprayed ceramic coatings. Examples of processing, microstructure and unique properties is provided through a description of thermal barrier coatings. Synthesis of dense ceramic coatings for wear and dielectric applications is also presented along with discussion of functional films produced both via traditional powder spray or suspension/precursor methods. Thermal spray will be continue to play an important role in ceramic coatings due to its cost advantages, flexibility and ubiquitous availability. Future expansion into functional coatings will require concerted, integrated, fundamental research in process and materials science, representing the next logical step in technology evolution.