【Report】2026.08.24 -197th Structural Materials Seminar- Dr. Sanjay Sampath (Department of Materials Science and Engineering Stony Brook University, New York, USA)
Prof. Sanjay Sampath (Back row, 5th from the right)
- Date and Time
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August 24, Mon. 2026. 10:30～11:30
- Location
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Conference Room, 5th Floor, Advanced Structural Materials Building, NIMS Sengen Site
- Title
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Thermal Spray as an Additive and Layered Manufacturing Technology
- Speaker
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Prof.Sanjay Sampath (Distinguished Professor)
Department of Materials Science and Engineering Stony Brook University, New York, USA
Abstract:(prepared by KAKISAWA)
As an innovative multilayer design for thermal barrier coatings (TBCs) used in gas turbine components, such as blades and vanes exposed to severe thermal cycling, Dense Vertically Cracked (DVC) coatings are proposed. Vertical segmentation cracks are intentionally introduced into dense thermally sprayed ceramic layers to enhance in-plane strain tolerance and relieve thermal stresses. Rather than treating cracks as defects, this approach utilizes controlled crack architecture as a functional microstructural feature. By combining dense, porous, graded, and vertically cracked layers, multiple functions—including thermal insulation, erosion resistance, and strain accommodation—can be integrated into a single TBC system, demonstrating Sampath’s concept of microstructure and defect architecture by design.
Another topic is the expansion of the conventional view of thermal spray from a coating process to a versatile layered manufacturing process. Thermal spray is not limited to depositing protective coatings on existing components; instead, it is regarded as a manufacturing platform capable of building materials, structures, and functions through controlled layer-by-layer deposition. A key advantage of this approach is the ability to control not only geometry, but also material composition, microstructure, and functionality during deposition. By increasing the deposited thickness, thermal spray can be extended from thin coatings to thick deposits, near-net-shape structures, and even free-standing components.