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Preparation of feedstock powders is the first step for synthesis of thermal spray coatings. A number of techniques that are capable of producing these materials include gas/water atomization, mechanical alloying/milling, thermo-chemical method, spray drying, agglomeration and sintering, plasma fusion, and sol–gel processing techniques (Berndt, 1992). Solid state synthesis is attributed to the chemical reaction and alloying performed at temperature which reactants are solid. As a result, the kinetics of solid state reactions are limited by the rate at which reactant species are able to diffuse across phase boundaries and through intervening product layers. Hence, the conventional solid state technique invariably require the use of high processing temperatures to ensure that diffusion rate is maintained at a high level (Schmalzried, 1995; Stein et al., 1993). More recently, the mechanical milling process has attracted considerable interest, primarily as a result of its potential to generate nanocrystalline and other non-equilibrium structures in large quantities at low temperature. This process is considered as a means to mechanically induced solid state reaction that occur in feedstock powder mixture during collision in the grinding media (Suryanarayana, 2001).

A Solid State Approach to Synthesis Advanced Nanomaterials for Thermal Spray Applications