The thermal spray industry has an estimated $4 to $5 billion in annual sales worldwide. Despite the widespread use of thermal spray, the science behind the process is still not fully understood. Thermal spray coatings have been traditionally designed empirically, with much trial and error in the laboratory, until a set of input parameters that produces a satisfactory coating is identified. Knowledge of the in-flight droplet behavior and spray plume characteristics is important to understanding the formation of thermal spray microstructures, which is in turn necessary for the prediction of thermal sprayed coating properties and performance. Since the quantity, concentration and distribution of oxides can affect coating properties and performance, an understanding of oxide formation processes is essential to control the quality of the resultant coatings. This book explains a key mechanism that underpins the oxidation process occurring during thermal spraying of aluminum. This book provides guidance for the thermal spray practitioner wishing to control the oxide content in thermal sprayed aluminum coatings.

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