• Stony Brook University

• Materials Science & Engineering Department

CTSR Director, Prof. Sampath was inducted into the ASM Thermal Spray Technology Hall-of-Fame in 2015. The Hall of Fame was established in 1993 to recognize outstanding leaders and significant contributors to the field of thermal spray. It represents the highest honor provided by ASM to the thermal spray community. Professor Sampath�s citation reads ��For innovative interdisciplinary thermal spray research bridging the gap between fundamental science and industrial practice through better understanding of coating properties and the development of advanced diagnostic tools.� Congratulations to Prof. Sampath .

Suspension plasma spray is an emerging technology to produce novel microstructures. Although the concept has been explored on and off for more than 2 decades, the advent of high power plasma torches, ability to reliably produce nanometric particle suspensions has enabled reconsideration of this technology as potential alternatives in certain applications. Of interest is the ability to produce thin, dense, electrolytes in solid oxide fuel cells, retaining anatase in TiO2 for photocatalytic surfaces and compliant thermal barrier coatings. Although much progress has been made in synthesizing microstructures, the events associated with material insertion into the plasma and coating formation dynamics are much more complex to interpret given the fine scale of the materials. CTSR in collaboration with Oerlikon Metco has initiated studies at understanding deposit evolution dynamics in particular through thickness crack formation in TBCs. Through real time curvature monitoring with our in situ coating property sensor, we are able to observe stress evolution and cracking during SPS deposition. This approach allows rapid scanning of process variables while recording the key events occurring within the process and correlating this with resultant microstructure. The associated figures shows examples of four types of microstructures and corresponding curvature � time graphs identifying the onset of through cracking events. Our preliminary results point to critical parameters in cracking relates to local deposition temp. and material application rate. Detailed analysis is being prepared in a publication.

The Consortium for Thermal Spray Technology hosted by CTSR continues to expand and provide benefits to industry across the supply chain. Recent additions to the group include General Motors and CoorsTek Ceramics Co. The Consortium is entering its 12th year starting from some 10 companies in 2002 to the present membership of 35 international companies. Each company contributes $12,500 annually as membership fees to the consortium enabling self-sustaining operations following the 11 year National Science Foundation Materials Research Center grant from 1996 to 2007.

The spring consortium meeting held on Stony Brook University campus was attended by more than 80 participants from the member companies. Over the span of two-days, CTSR staff, students and collaborators presented updates on both science and technology as well as their value to industrial operations. As noted earlier, since 2010 the fall meetings are rotated around OEM partner sites to facilitate interest within large equipment integrators. Fall 2015 meeting will be held on Nov.17h and 18th at the Cummins Engine Company in Columbus Indiana. This meeting follows successful past events at Naval Research Lab (2010), GE Aviation Learning Center (2011), Boeing Museum of Flight (2012), Tinker AF Base in Oklahoma city (2013), and Applied Materials (2014). This allows larger participation of design and manufacturing engineers from these organizations which will be crucial to enhance thermal spray coating utilization in engineering systems. This particular meeting is also an opening into the automotive sector which is re-examining thermal spray for a host of new applications.