Plasma and Thermal Spray Coatings: Challenges, Developments and Future Perspectives

Dear Colleagues,

Protective coatings produced by plasma and thermal spray technologies have become indispensable for enhancing the performance and longevity of materials in a wide range of industrial applications. These processes, which allow for the deposition of high-performance coatings on various substrates, have seen significant advancements, driven by both fundamental research and growing industrial demands. From aerospace to automotive, and energy to manufacturing, the need for coatings that can withstand extreme conditions, including high temperatures, wear, corrosion, and oxidation, has catalyzed remarkable progress in plasma and thermal spray technologies.

The potential of these techniques to create coatings with tailored properties—ranging from high-temperature resistance to improved mechanical strength—has made them central to the development of next-generation protective materials. With a deepened understanding of the underlying mechanisms and continuous innovation in processing methods, plasma and thermal spray technologies are now capable of delivering coatings with exceptional durability and multiple functionalities.

Despite significant advancements, several challenges remain in the field of plasma coatings and thermal spray technologies. Key issues include optimizing process efficiency and material utilization to reduce energy consumption and carbon emissions. Furthermore, the reliance on critical raw materials—such as rare earth elements and strategic metals—raises concerns regarding supply security and environmental impact. Addressing these challenges is essential for aligning these processes with the principles of green technologies, particularly in sectors like renewable energy, aerospace, and clean transportation, where sustainable surface engineering plays a crucial role.

This Special Issue aims to highlight both the fundamental principles and cutting-edge industrial applications of plasma and thermal spray coatings. The scope of the issue encompasses:

• In-depth theoretical and experimental research on the fundamental mechanisms of plasma and thermal spray processes and their influence on coating microstructures and properties.
• Advancements in next-generation coatings produced through plasma and thermal spray technologies, including novel materials, new materials generation (composition, architecture, etc.) and hybrid systems.
• High-performance coatings for extreme environments, focusing on their applications in industries such as aerospace, automotive, energy, and manufacturing.
• Challenges faced in the development and application of plasma and thermal spray coatings, including issues related to process optimization, coating integrity, and performance in demanding conditions.
• Future perspectives on the evolution of these technologies, with an emphasis on emerging trends, new materials, and potential innovations.

This Special Issue serves as a forum for exploring the diverse and evolving landscape of plasma and thermal spray coatings, offering insights into the latest developments, addressing current challenges, and presenting new directions for future research and industrial practice.

Dr. Marjorie Cavarroc-Weimer
Dr. Angéline Poulon-Quintin
Guest Editors

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• plasma-based PVD deposition processes
• thermal-spray-based deposition processes
• gigh-performance coatings
• environmentally friendly coating processes
• surface engineering