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Oxide dispersion strengthened alloys (ODS), although not commonly used in coating applications, have long been used for high-temperature structural applications due to their superior creep properties. In this paper, we present the design, synthesis, and characterization of a new class of functionally engineered high-temperature coatings in which ultrafine oxide particulates are dispersed in the matrix alloy to achieve superior creep resistance along with improved high-temperature corrosion and erosion resistance. These coatings were fabricated using a novel technique called ''hybrid spray process''. Hybrid spray technique combines arc spray and high-velocity oxy fuel (HVOF) spray processes; the metallic matrix alloys are fused by the wire arcing component of the process, whereas the ultrafine particles are synthesized in-flight by the HVOF component from liquid precursors. These particulate dispersed hightemperature composite coatings were fabricated using liquid precursors for SiO 2 , Cr 2 O 3 , Al 2 O 3 , and wire feed stock of 55/45 NiCr, in one step. The coatings were then characterized using electron microscopy (SEM/TEM) and thermogravimetric analysis (TGA). High-temperature erosion, oxidation, and corrosion performance of these coatings were also evaluated and compared with 304 stainless steel, arc sprayed NiCr coatings as well as Alloy 625 overlay cladding. The hybrid spray process produced dense coatings with uniform dispersion of the ultrafine oxide particles. Further, these coatings also demonstrated superior corrosion, erosion, and oxidation resistance; SiO 2 particulate dispersion being most effective in terms of high-temperature corrosion resistance.

In recent studies, titania has been added to hydroxyapatite (HA) coatings to impart photocatalytic properties. The benefits of such additions are maximized when titania is in nanocrystalline anatase form. In this study, nano-titania was synthesized in-flight from a liquid precursor consisting of ethanol and titanium isopropoxide. The precursor and HA powder were fed into a plasma gun, forming nano-titania particles that embedded in the HA. Coatings of pure titania and titania-embedded HA were deposited under different spray conditions on titanium coupons and then characterized via XRD and SEM analysis. The titania coatings contained ultrafine anatase and rutile particles with anatase being favored by more power input and rapid quenching. The composite coatings contained dispersed ultrafine titania particles in a matrix consisting primarily of HA with trace amounts of calcium phosphate and amorphous phases. The effect of spraying parameters on phase and microstructure evolution is discussed as well.

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