Over the last century, thermal spray coatings have found wide spread applications in a diverse array of industries: from automotive to aerospace to medical implants. From its humble beginnings through flame spraying of zinc for cathodic protection to advanced functional oxides in energy systems, the technology and industry have enjoyed impressive growth with an estimated value of some $ 6B per year worldwide. In the US, much of the early developments and rapid growth in the 1960s and 1970s were driven by aerospace systems particularly due to extraordinary demands on materials imposed in high temperature turbines. Translating these early successes to other industrial sectors turned out to be a challenging task and met with mixed successes in recent years. This presentation will examine critical attributes of coating integration into systems from both historical and contemporary perspectives and explore future needs in science and technology to address emergent coating applications. Of particular interest is also consideration of advanced technologies and scientific knowledge into existing and emerging thermal spray processes. This presentation will also provide an assement of historical evolution of the thermal spray application within the US and examine key successes along with challenges and opportunities for the future.
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