Abstract: A method for coating materials on substrates is disclosed which includes providing a dispersion of the coating material in a liquid carrier wherein the material includes individual, non-agglomerated particles having diameters of less than 500 nanometers, injecting the dispersion into a thermal spray to form droplets of liquid carrier and particles, burning the droplets of liquid carrier and particles within the thermal spray so the particles begin to melt and wherein, as the droplets burn, at least some of the particles begin to form agglomerates of particles within the droplets and directing the droplets containing the agglomerates of particles toward the substrate to coat the substrate with the particles.