Plasma spray processing is a droplet deposition method that combines t
he steps of melting, rapid solidification, and consolidation into a si
ngle step. The versatility of the technology enables the processing of
free-standing bulk, near-net shapes of a wide range of alloys, interm
etallics, ceramics, and composites, while still retaining the benefits
of rapid solidification processing. In particular, it is possible to
produce dense forms through vacuum plasma spraying.