Thermal Spray Maps: Material Genomics of Processing Technologies


There is currently no method whereby material properties of thermal spray coatings may be predicted from fundamental processing inputs such as temperature-velocity correlations. The first step in such an important understanding would involve establishing a foundation that consolidates the thermal spray literature so that known relationships could be documented and any trends identified. This paper presents a method to classify and reorder thermal spray data so that relationships and correlations between competing processes and materials can be identified. Extensive data mining of published experimental work was performed to create thermal spray property-performance maps, known as “TS maps” in this work. Six TS maps will be presented. The maps are based on coating characteristics of major importance; i.e., porosity, microhardness, adhesion strength, and the elastic modulus of thermal spray coatings.

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Atmospheric plasma spray


American Society for Testing and Materials


Controlled atmosphere plasma spray


Cold spray

D-Gun® :

Detonation gun spray


Flame spray




Rockwell hardness C-scale


High-velocity oxygen fuel spray


High-velocity suspension flame spray


Low pressure plasma spray


Plasma-transferred wire arc spray


Radio frequency


Standoff distance


Suspension plasma spray


Solution precursor plasma spray


Tensile adhesion test


Thermal barrier coating


Thermal spray


Flame temperature and particle velocity


Twin Wire Arc


Vacuum plasma spray


Tungsten monocarbide


Tungsten carbide-cobalt


Water-stabilized plasma spray


Yttria-stabilized zirconia


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This work was supported under a Swinburne University Postgraduate Research Award. We also acknowledge support from the Defence Materials Technology Centre (DMTC).

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Correspondence to Andrew Siao Ming Ang.

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Ang, A.S.M., Sanpo, N., Sesso, M.L. et al. Thermal Spray Maps: Material Genomics of Processing Technologies. J Therm Spray Tech 22, 1170–1183 (2013).

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  • adhesion
  • data mining
  • elastic modulus
  • genomic analysis
  • hardness
  • property map
  • sliding wear
  • spray parameters
  • thermal spray