This fully revised, industry-standard resource offers practical details on every aspect of the fundamentals necessary for understanding thermal spray technology, from powder all the way to the final part. The second edition is presented in a reader-friendly format that is split into four parts. Part I presents a review of thermal spray coating and its position in the broad field of surface modification technologies. Highlights of combustion and thermal plasmas are given with an expanded treatment of in-flight plasma-particle interactions. The second and third parts deal respectively with an updated presentation of thermal spray technologies and coating formation, including solution and suspension plasma spraying. The last part of the book includes a comparative analysis of different thermal spray processes, which is essential for the optimal selection of the appropriate thermal spray process in a given application. Coverage of system integration has been expanded with the addition of adetailed discussion of online instrumentation and process diagnostics and numerous examples of industrial scale spray booth designs. Attention is also given to coating finishing and health and safety issues. An extensive review is presented of thermal spray applications grouped in terms of process objectives and present use in different industrial sectors. This book will serve as an invaluable resource as a textbook for graduate courses in the field and as an exhaustive reference for professionals involved in the thermal spray field. This fully revised, industry-standard resource offers practical details on every aspect of the fundamentals necessary for understanding thermal spray technology, from powder all the way to the final part. The second edition is presented in a reader-friendly format that is split into four parts. Part I presents a review of thermal spray coating and its position in the broad field of surface modification technologies. Highlights of combustion and thermal plasmas are given with an expanded treatment of in-flight plasma-particle interactions. The second and third parts deal respectively with an updated presentation of thermal spray technologies and coating formation, including solution and suspension plasma spraying. The last part of the book includes a comparative analysis of different thermal spray processes, which is essential for the optimal selection of the appropriate thermal spray process in a given application. Coverage of system integration has been expanded with the additionof a detailed discussion of online instrumentation and process diagnostics and numerous examples of industrial scale spray booth designs. Attention is also given to coating finishing and health and safety issues. An extensive review is presented of thermal spray applications grouped in terms of process objectives and present use in different industrial sectors. This book will serve as an invaluable resource as a textbook for graduate courses in the field and as an exhaustive reference for professionals involved in the thermal spray field. Reviews the state of the art in thermal spray technology; - Provides an update of spray torch designs supported by modelling studies and the relationship between process parameters and coating properties; - Comparative analysis of thermal spray technologies and spray system integration. Maher I. Boulos, Professor Boulos is professor emeritus at the chemical engineering and Biotechnology Engineering Department of the University of Sherbrooke, in Sherbrooke, Québec Canada. He obtained his bachelor’s degree in chemical Engineering from Cairo University, Egypt 1963, and Master’s and Ph.D. degrees from the University of Waterloo, Ontario, Canada in 1968 and 1972. He has a long experience in the areas of fluid dynamics and heat and mass transfer under plasma conditions. He has been at the University de Sherbrooke since 1973 where he founded the Plasma Technology Research Center in 1985. In 1990, he founded Tekna Plasma Systems Inc., a spin-off the University of Sherbrooke with the mandate of developing and promoting industrial applications of thermal plasma technology. Since January 2007 he retired from his regular faculty position to focus on running the Tekna Group which has grown to be a world leader in induction plasma technology. Over his 35 years career at the University of Sherbrooke, Professor’s Boulos supervised/co-supervised 57 M.Sc. and Ph.D. students, published more than 150 papers in refereed scientific Journals, more than 200 International conference proceedings, and contributed to 35 patents and patent applications. He coauthored a textbook on thermal plasma fundamentals and applications, published by Plenum in 1994 and numerous chapters in textbooks. He is a Fellow of the Canadian Academy of Engineering and has been the recipient of numerous distinctions including TSS Hall of Fame in 2003 and the “Lieonel Boulet” Prix du Québec in November 2007, the highest scientific dis