This book details the emerging area of the induction of expert systems in thermal spray technology, replacing traditional parametric optimization methods like numerical modeling and simulation. It promotes, enlightens, and hastens the digital transformation of the surface engineering industry by discussing the contribution of expert systems like Machine Learning (ML) and Artificial Intelligence (AI) toward achieving durable Thermal Spray (TS) coatings. Artificial Intelligence and Machine Learning in the Thermal Spray Industry: Practices, Implementation, and Challenges highlight how AI and ML techniques are used in the TS industry. It sheds light on AI’s versatility, revealing its applicability in solving problems related to conventional simulation and numeric modeling techniques. The book combines automated technologies with expert machines to show several advantages, including decreased error and greater accuracy in judgment, and prediction, enhanced efficiency, reduced time consumption, and lower costs. Specific barriers preventing AI's successful implementation in the TS industry are also discussed. The book also looks at how training and validating more models with microstructural features of deposited coating will be the center point to grooming this technology in the future. Lastly, the book thoroughly analyzes the digital technologies available for modeling and achieving high-performance coatings, including giving AI-related models like Artificial Neural Networks (ANN) and Convolutional Neural Networks (CNN) more attention. This reference book is directed toward professors, students, practitioners, and researchers of higher education institutions working in the fields that deal with the application of AI and ML technology.

This book provides the latest information about the research being conducted and established solutions available in the field of thermal spray coatings for various engineering applications. The readers of this book will be mainly the graduates, engineers and researchers who are pursuing their carrier in the field of thermal spraying. This book will cover the studies and research works of reputed scientists and engineers who have developed thermal spray coatings for thermal protection, bio-implants, renewal energy, wear and corrosion in hydraulic turbines and jet engines, hydrophobic surfaces etc. Hence, the book serves as a valuable resource of latest advancement in thermal spray technology and consolidated references for aspirants and professionals of surface engineering community. The book covers following topics for different industrial applications: Introduction: Historical developments, Science and Engineering aspects of thermal spray coating technology and different thermal spray coatings techniques and its comparison with other fabrication processes. Recent advancements and applications of thermal spray coatings Cold spray technology for additive manufacturing. High-temperature corrosion and erosion resistant coatings and thermal barrier coatings for power plants, automotive sector, and jet engines. Erosion and corrosion-resistant coatings for hydro-power plants, offshore, chemical and oil industries. Bio-coatings for human body implants. Thermal spray coating for super-hydrophobic surface. 3. Case study of boiler tubes failure and prevention by thermal spray coatings.