Thermal Spray Technology: From Cold Spray to AI-Driven Innovations

A variety of coating techniques fall under the umbrella of thermal spray technology, such as the more contemporary cold gas dynamic spray, in which solid powder particles are driven by a de Laval nozzle to strike and form a bond with a substrate without melting. The principles, benefits, and drawbacks of several thermal spray techniques—such as cold spray, high-velocity oxygen fuel (HVOF) spraying, wire arc spraying, and plasma spraying—are thoroughly discussed in this study. Additionally, it goes into great length about the background and uses of cold spray. The potential of Artificial Intelligence (AI) and Machine Learning (ML) to transform thermal spray processes through process optimisation, coating quality prediction, defect detection, and material design is also introduced in this paper, acknowledging the growing importance of data-driven approaches in materials science and opening the door for intelligent coating solutions.