The next generation of thermal barrier coatings (TBCs) for gas turbine engines, high-performance coatings for wear protection, new-designed electrode/electrolytic components for solid oxide fuel cells (SOFCs), enhanced biocompatible coating structures for implants, superhy drophobic coatings for aircraft wings and wind turbine blades are some of the major applications that urge research on suspension thermal spray (STS) process. Possibilities of technological evolution are immense. Nonetheless, it is interesting to understand how it all started. The thermal spraying of suspensions and liquid precursors has demonstrated a huge driving force for growth since their inceptions. The first sets of information in the ‘‘standard open literature’’ (i.e., journals, conference proceedings, and patents) showing that liquid carrier feedstocks that could actually be thermally sprayed became available in 1997, i.e., approximately two decades ago. These were pioneer studies led by the University of Sherbrooke (Canada) on suspension spraying and Stony Brook University (USA) on liquid precursor spraying. At this time, the plasma spraying of suspensions became known as suspension plasma spray (SPS), whereas the plasma spraying of liquid precursors became known as solution precursor plasma spray (SPPS). In this manuscript, the expression STS refers to suspensions sprayed via different thermal spray techniques, e.g., plasma spray and HVOF. Today STS is one of the most important R&D venues in thermal spray processing and now it is an industrial process. Many research centers, universities, and industries all over the world are expending a considerable amount of resources in the technology. Moreover, the number of graduate students and postdocs working on STS is on the rise. In addition, to better understand why STS is a revolution in thermal spray and why STS differs so much from traditional thermal spray coating processing, it is necessary to highlight the major differences between both techniques.
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