Sanjay Sampath¹; ¹Stony Brook University

Overlay coatings find extensive applications in industry serving to protect components from wear, heat, electrical damage and corrosion. Coatings are first lines of defense for structures and components subjected to extreme environments. Specifically thermal sprayed coatings are used in aerospace, energy, heavy machinery, automotive and electronics. Coatings are various types including ceramics, materials, cermets and composites based on combinations there-of. Much of the current thermal sprayed overlays and usually monolithic single layers. However, there are many applications where the coating attributes needs to be multifunctional, especially where a variety of environmental degradation mechanisms occur concurrently. One approach to seek multifunctionality is through 2D/3D layered design and manufacturing. Thermal spray naturally lends itself to such opportunities as coatings are built in layers allowing optimization of chemistry, stress and microstructure through thickness. This presentation will overview examples of these strategies for applications and identify the fundamental issues.