Volcanic ash ingested by jet engines can damage conventional Y2O3‐stablized ZrO2 thermal barrier coatings (TBCs) used to protect engine parts in the hot section. Newer TBCs, one based on Gd2Zr2O7 and another composed of ZrO2 solid solution containing Y2O3, Al2O3, and TiO2, are found to be highly resistant to such damage from Eyjafjallajökull volcano ash. Photo courtesy of Peter Greenfield.

Considerable progress has been made over the last decades in thermal spray technologies, practices and applications. However, like other technologies, they have to continuously evolve to meet new problems and market requirements. This article aims to identify the current challenges limiting the evolution of these technologies and to propose research directions and priorities to meet these challenges. It was prepared on the basis of a collection of short articles written by experts in thermal spray who were asked to present a snapshot of the current state of their specific field, give their views on current challenges faced by the field and provide some guidance as to the R&D required to meet these challenges. The article is divided in three sections that deal with the emerging thermal spray processes, coating properties and function, and biomedical, electronic, aerospace and energy generation applications.

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The fabrication of thin oxide films at low temperatures using simple processes has been a significant challenge associated with expanding the potential applications of these materials. Recent developments have demonstrated that the photo-assisted chemical solution deposition (PACSD) process offers a promising means of solving these difficulties, allowing high volume, on-demand production of variable sample sizes using an advantageous wet process. A better understanding of the crystal growth phenomena associated with this process, however, is required to enable various oxide thin films to be prepared using this new concept. Under pulsed ultraviolet (UV) laser irradiation, crystal growth has been confirmed to proceed by near-instantaneous photothermal heating and photochemical effects at the reaction interface. Vacuum UV lamp irradiation is also a useful means of generating oxide nuclei, since it results in effective chemical bond cleavage and simultaneously produces reactive oxidant (O3/O((1)D)) species. In this review, the nucleation and growth mechanisms which occur during the PACSD process are introduced and discussed and we examine the future possible applications of this process.

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