Abstract: A method for producing a solid and/or porous film Includes preparing a suspension of solid particles in a solvent and spreading the suspension as a uniform layer of powder particles on a high melting point support. The solvent is eliminated so as to dry the uniform layer of powder particles into a dried porous uniform layer and surface melting/sintering of the dried uniform layer is carried out by direct contact with a concentrated heat source having a controlled gas composition so as to melt/sinter the layer into a solid/porous film.

Abstract: The plasma spray method produces a material deposit on a substrate to form either a protective coating of a near net shape body, or produces a powder of a given material. The material is supplied to a plasma discharge in the form of a suspension comprising small solid particles of that material dispersed into a liquid or semi-liquid carrier substance. The suspension is brought into the plasma discharge by an atomizing probe using a pressurized gas to shear the suspension and thus atomize it into a stream of fine droplets. The plasma discharge vaporizes the carrier substance and agglomerate the small solid particles into partially or totally melted drops which are accelerated to hit the substrate and form thereon the coating or near net shape body. Alternatively, the molten drops can be solidified in-flight and collected into a vessel to produce a powder of that material.