*Christopher C. Berndt, A.S.M. Ang, Swinburne University of Technology, Melbourne, Australia
Thermal spray processes fall under the umbrella of additive manufacturing. These coatings function under harsh environments; e.g., high temperature, aggressive wear, and corrosion within applications such as power generation, the transportation industries, petro-chemical plants and bioengineering. This presentation focuses on the microstructural nature of thermal spray coatings and how the materials engineering design of future applications is driving fundamental R&D. Furthermore, recent advances to commercialise thin thermal spray coatings that are manufactured under ambient atmospheric conditions will be described. The goal is for thermal spray to enter new markets; e.g., sensors, hydrophobic/hydrophilic films, electronic circuits etc., and other endeavours that are on the near-term horizon.