Transforming Thermal Spray Technology through Interdisciplinary Research: From Protective Coatings to Functional Multilayers

Thermal spraying is a directed melt spray deposition process, in which inorganic particles in the diameter range of 1-100 microns are heated, melted (in some cases partially), propelled and impacted onto a prepared substrate. A rapid sequence of events occurs including: melting, impact (in some cases shock), spreading and rapid solidification, all of which take place in microsecond timescales, enabling materials synthesis from extreme conditions. These situations offer a rich opportunity for materials research of far-from-equilibrium materials and micro/nano-structures. Concomitantly, the versatility and flexibility with respect to materials and processes has enabled thermal spray to find wide-spread industrial applications. They are crucial to the economic and efficient operation of a range of engineering systems including gas turbines engines (for propulsion and energy), biomedical implants, industrial machinery, automotive components and semiconductor manufacturing.

Over the last 12 years through support from the National Science Foundation-Materials Research Science and Engineering Centers program, Center for Thermal Spray Research at Stony Brook has enabled a multidisciplinary group of investigators to critically examine the scientific underpinning behind thermal sprayed materials and unravel its complexity for enhanced utilization. Major advances have been made on a number of fronts including processing science, multi-scale characterization of complex defected structures, and novel means of property extraction of layered materials. Notable contributions include the discovery of anelastic energy absorbing mechanisms in thermo-structural ceramic coatings, anisotropy and size dependent functional properties, shock induced phase transformations in semiconductors etc. In addition, new materials opportunities has been enabled by expanded synthesis capabilities via precursor based thermal spray deposition with applicability in nanosciences and materials.

Furthermore, under the auspices of DARPA's Mesoscopic Integrated Conformal Electronics program breakthrough new 3D patterning capabilities have been created (direct write) that has the potential to propel thermal spray from traditional coating applications to printed electronics, sensors and multilayer devices.

These interdisciplinary studies have yielded rich dividends to science, technology and even human resources. This presentation will highlight past contributions and seek new opportunities in emergent coatings, synthesis and multiscale assembly of novel materials, and patterned functional devices.