348 Pages 151 B/W Illustrations
    by CRC Press

    This book discusses the concepts and uses of thermal spraying including starting powder, spraying parameters, diagnostics, coating deposition, evolved microstructure and resulting properties complemented with several case studies to associate the learnings with applied concepts. The major parts of the instrumentation, the spraying gun, which is the fundamental aspect of different thermal spraying conditions are also discussed. Solved examples, numerical problems and descriptive questions are included for self-assessment at the end of every chapter.

    The book:

    • Discusses all aspects from starting powder, spraying parameters, diagnostics and coating deposition;
    • Explores schematics to highlight the conceptual notes;
    • Includes multiple case studies from domains including aerospace, biomedical, manufacturing, wettability and others to highlight the practical application of thermally sprayed coatings;
    • Covers classification of thermal spray techniques; and
    • Contains solved example, numerical problems and descriptive questions for self-assessment.

    This book is aimed at senior undergraduates and graduates in materials science and engineering.

    Chapter 1 Development of Thermal Spray Techniques and Applications
    Raghav Mittal, Ariharan S, Rubia Hassan, Alok Bhadauria and Kantesh Balani

    Chapter 2 Surface Coatings
    Shipra Bajpai, K. Vijay Kumar, Anup. K. Keshri and Kantesh Balani

    Chapter 3 Classification of Thermal Spray Techniques
    Alok Bhadauria, Divya Rana and Kantesh Balani

    Chapter 4 Spraying Parameters
    Ariharan S., Rubia Hassan and Kantesh Balani

    Chapter 5   Design of Spray Guns
    Priya Kushram, Ariharan S, Alok Bhadauria, Ritik Tandon, Rubia Hassan and Kantesh Balani

    Chapter 6 Powder Characterization and Synthesis
    Rubia Hassan, and Kantesh Balani

    Chapter 7 Coating Formation
    Shipra Bajpai and Kantesh Balani

    Chapter 8 Testing of Coatings
    Rubia Hassan, Ashutosh Tiwari and Kantesh Balani

    Chapter 9 Testing of Coatings
    Roopal Singh, K. Vijay Kumar and Anup Kumar Keshri

    Chapter 10 Bulk Nanostructure and Near-Net Shape
    Ariharan S and Kantesh Balani

    Chapter 11 Case Studies
    Moumita Mistri, Shivani Gour, Alok Bhadauria, K. Vijay Kumar, Ariharan S, Rubia Hassan, Pooja Rani, Ashutosh Tiwari, Anup K. Keshri and Kantesh Balani


    Ariharan S earned his doctorate in Materials Science and Engineering from Indian Institute of Technology (IIT) Kanpur, India, in 2018. He is recipient of the Nanomaterials and Energy Prize 2019 by the journal Nanomaterials and Energy. He was awarded a National Post-Doctoral Fellowship 2018, SERB, Government of India, during February 2019–August 2021 at IIT Madras. Currently, he is a post-doctoral researcher at Alexander Dubček University of Trenčín, Slovakia. He has published more than 25 research articles (h-index of 13, i10-index of 13) with 450+ citations in peer-reviewed journals and conference proceedings.

    Rubia Hassan earned a PhD from the Department of Materials Science and Engineering at IIT Kanpur, India, in February 2022. She is a recipient of the prestigious Prime Ministers Research Fellowship. She is a recipient of the Bogineni Chenchu Raman Naidu Gold Medal and the Cadence Gold Medal, recognizing her academic excellence. She has co-authored eight research papers published in reputed international journals.

    Alok Bhadauria is a post-doctoral fellow in the Materials Science and Engineering Department at IIT Kanpur, India. He earned a PhD from the Metallurgical and Materials Engineering Department at IIT Kharagpur, India. He has published 13 technical papers in peer-reviewed journals and is currently working in alumina and yttria-stabilized zirconia (YSZ)-based thermal barrier coatings for high-temperature gas-turbine engine blades.

    Ashutosh Tiwari is Dean (PG and Research) and Registrar at Rajkiya Engineering College Banda, Uttar Pradesh, India. He is a member of the Indian Nuclear Society, a life member of the Indian Association of Physics Teachers, the Indian Society of Technical Education, and the Indian Science Congress. He bagged the DST TARE project and has received various fellowships, such as the IGCAR Post-Doctoral Fellowship, the Dr D.S. Kothari Post-Doctoral Fellowship of UGC, an institute post-doctoral fellowship at IIT Kanpur, and SRF and JRF from CSIR New Delhi. He has published a book on nuclear science. He has 11 years of teaching experience and has published 25+ papers in various international journals. His research interests are safety analysis of power plants, thermal barrier coatings and development of virtual labs.

    Ritik Tandon studied Chemical Engineering at Purdue University, West Lafayette, Indiana, USA. He is involved with Anod Plasma Spray Limited, Kanpur, India, in the area of repair, refurbishment and coating of turbine components for end use in power generation. His firm offers services in industrial, hydro and thermal sectors. His company enjoys an excellent reputation with esteemed customers like NTPC, NHPC, BHEL and RIL, and has been associated with Mitsubishi Heavy Industries in repair and coating of gas turbine components for more than 25 years.

    Anup Kumar Keshri is an assistant professor in the Department of Metallurgical and Materials Engineering at IIT Patna, India. He earned his PhD degree in Materials Science and Engineering from Florida International University (FIU), Miami, Florida, USA, in July 2010. He has published 75+ papers in peer-reviewed journals and has an h-index of 28 (2600+ citations), which strongly endorses his research productivity. He has filed five Indian patents, two of which have been granted. He is a recipient of awards including a Research Stay Grant by the Humboldt Foundation, a Dissertation Year Fellowship (2009–2010) from FIU, the Arthur E. Focke Leadership Award by ASM Foundation, and delegate of President’s Council of Student Advisors (PCSA) formed by the American Ceramic Society (ACerS). He also serves as a reviewer for several journals in the areas of coatings and thermal spray.

    Kantesh Balani is Full Professor in the Department of Materials Science and Engineering, IIT Kanpur, India, since November 2018. He earned his doctorate in Mechanical Engineering from FIU in 2007. He has published over 170 articles (h-index of 40, i10-index of 120+) with 7500+ citations in peer-reviewed international journals. He is a recipient of the Yadupati Singhania Memorial Chair, an ASM Class of Fellow 2021, a Fellow of INAE 2021, a Fellow of NASc 2021, the Swarnajayanti Fellowship 2017–23, and the P.K. Kelkar Research Fellowship. He is co-inventor of three Indian patents (11 filed), the co-author of two books, and is a reviewer of 50+ journals. He is Editor in Chief of Nanomaterials and Energy, Associate Editor of Journal of Thermal Spray Technology, Principal Editor of Journal of Materials Research and Key Reader of Metallurgical and Materials Transactions A.