Sanjay Sampath

SUNY Distinguished Professor, Joint appointment with Mechanical Engineering at Stony Brook University

Research Expertise

Materials

About

Dr. Sanjay Sampath, is currently *Distinguished Professor* of Materials Science and Engineering at Stony Brook University (SUNY) and director of the Center for Thermal Spray Research ([www.sunysb.edu/ctsr](http://www.sunysb.edu/ctsr)) an interdisciplinary industry-university partnership in the field of thermal spray materials processing and surface engineering.  CTSR was created in 1996 through the National Science Foundation’s Materials Research Science and Engineering Centers. He received his Ph.D. degree from Stony Brook in Materials Science in 1989.  After graduating, he spent four years at GTE Sylvania involved in research, development, and processing of refractory metal compounds and composites.  Upon joining the faculty at Stony Brook University in 1993, Dr. Sampath has directed research efforts on various federal and industrially funded programs.  Under the auspices of the NSF Center, he directed a group of a dozen or so interdisciplinary faculty members towards fundamental understanding of thermal spray processes, materials and applications.  The self-sustaining Center (since 2005) is home to the Industrial *Consortium for Thermal Spray Technology* comprising of 35 leading companies aimed at knowledge transfer from fundamental research to applications.   He was also principal investigator on the DARPA Mesoscale Integrated Conformal Electronics (MICE) project enabling 3D printing of sensors via direct write thermal spray technology. Dr. Sampath has 180 journal publications to his credit, 13 patents and winner of several best paper awards.  He has advised more than 40 MS and PHD students over 20 post-doctoral fellows and more than 100 undergraduates. He received the SUNY Chancellor’s Award for excellence in scholarship and creative activities in its inaugural year, was elected Fellow of ASM International, recipient of 2007 R&D 100 award for developing direct write technology  and was inducted as Fellow of the American Ceramic Society.  In 2011, he was recognized as a State University of New York Distinguished Professor, highest faculty designation of the SUNY system. In 2015 he was inducted into the Thermal Spray Society Hall-of-Fame.  In 2017 he received the Application to Practice Award from TMS the Materials Society. In 2019 he received the John Jeppson Award from American Ceramic Society and the 2020 Albert Sauveur Award from ASM International. In 2023 he was elected as Academician of the World Academy of Ceramics and receive the Rishi Raj Medal for Innovation and Commercialization from American Ceramic Society in 2024.

Legacy Map

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Publications

In situ measurement of residual stresses and elastic moduli in thermal sprayed coatings
Acta Materialia
2003
Micro-indentation and inverse analysis to characterize elastic–plastic graded materials
Materials Science and Engineering: A
2003
Functionally graded WC–Co/NiAl HVOF coatings for damage tolerance, wear and corrosion protection
Surface and Coatings Technology
2012
Embedded Resistive Strain Sensors for Harsh Environments
2006 IEEE Aerospace Conference
Formation Mechanisms, Structure, and Properties of HVOF-Sprayed WC-CoCr Coatings: An Approach Toward Process Maps
Journal of Thermal Spray Technology
2014
Plasma spray consolidation of high temperature composites
Materials Science and Engineering: A
1991
An Integrated Assessment of Process-Microstructure-Property Relationships for Thermal-Sprayed NiCr Coatings
Journal of Thermal Spray Technology
2011
An X‐Ray Photoelectron Spectroscopic Study of the Passive Film Formed on Pure Mo and MoSi2 in 4M HCl
Journal of The Electrochemical Society
1995
Optimizing Compliance and Thermal Conductivity of Plasma Sprayed Thermal Barrier Coatings via Controlled Powders and Processing Strategies
Journal of Thermal Spray Technology
2012
Plasma Sprayed Ni–Al Coatings
Surface Engineering
1989
Melting Behavior of In-Flight Particles and Its Effects on Splat Morphology in Plasma Spraying
Heat Transfer, Volume 7
2002
Through-Thickness Residual Stress Measurement in Metal and Ceramic Spray Coatings by Neutron Diffraction
Materials Science Forum
2008
Plasma sprayed Mo–Mo oxide nanocomposites: synthesis and characterization
Surface and Coatings Technology
2001
Effect of Microstructure and Alloy Additions on the Sliding Friction and Wear of Plasma Sprayed Molybdenum Alloy Coatings
International Thermal Spray Conference
1998
Inhibition of molten droplet deposition by substrate surface hydroxides
Surface and Coatings Technology
2011
Sensors for harsh environments by direct write thermal spray
Proceedings of IEEE Sensors
Using Thermal Spray and Laser Micromachining to Fabricate Sensors
Journal of Thermal Spray Technology
2011
Comparison of Coating Stresses Produced by High Velocity Liquid/Gas Fuel and Triplex Pro 200 Plasma Processes using In-Situ Coating Stress Measurement
International Thermal Spray Conference
2008
Curvature changes during thermal cycling of a compositionally graded NiAl2O3 multi-layered material
Materials Science and Engineering: A
1996
Spray Forming of MoSi2 and MoSi2-Based Composites
MRS Proceedings
1990
Residual Stress Analysis of Thermal Sprayed Molybdenum Deposit
Materials Science Forum
2005
Plasma spray forming of intermetallics and their composites\
Journal of Thermal Spray Technology
1994
Functionally Graded Materials for Gun Barrels
Ceramic Engineering and Science Proceedings
Neutron Diffraction Residual Stress Measurement on Thermally Sprayed Coatings
International Thermal Spray Conference
1997
Iron-Based Deposits Produced by High-Throughput Water Stabilized Plasma
International Thermal Spray Conference
1996
Influence of Pores and Cracks Morphology on Mechanical Behavior of Thermally Sprayed Ceramics
International Thermal Spray Conference
2010
Processing-Microstructure-Property Relations in Anisotropic Thermal Sprayed Composites
MRS Proceedings
2006
Effect of Injection Angle on Particles In-Flight Characteristics
9th AIAA/ASME Joint Thermophysics and Heat Transfer Conference
2006
Microstructure Development During Plasma Spraying of Molybdenum Part 2: Coating Microstructure and Properties
International Thermal Spray Conference
1998
Effect of Thermal Gradient on the Through‐Thickness Thermal Conductivity of Plasma‐Sprayed TBCS
Ceramic Engineering and Science Proceedings
2010
331 Microstructure Evolution in Thermal Spray Coatings and its relevance in High Temperature Behavior
Proceedings of the 1992 Annual Meeting of JSME/MMD
2005
Effect of Deposition Rate on the Stress Evolution of Plasma-Sprayed Yttria-Stabilized Zirconia
Journal of Thermal Spray Technology
2012
Anelastic Behavior of Plasma‐Sprayed Zirconia Coatings
Journal of the American Ceramic Society
2008
Dilation Behavior of Thermal Spray Coatings
Journal of Thermal Spray Technology
2019
Processing effects on in-flight particle state and functional coating properties of plasma-sprayed manganese zinc ferrite
Materials Science and Engineering: B
2011
Experimental and Numerical Studies of Plasma Forming Process Parameters Effect on Optimum Particle Impact Locations
International Thermal Spray Conference
2007
Particle Injection in Direct Current Air Plasma Spray: Salient Observations and Optimization Strategies
Plasma Chemistry and Plasma Processing
2007
Embedded Temperature and Heat Flux Sensors for Advanced Health Monitoring of Turbine Engine Components
2006 IEEE Aerospace Conference
Optimizing Nonlinear Properties of Thermal Sprayed Coatings through Processing Parameters
MRS Proceedings
2006
Ambient and High-Temperature Thermal Conductivity of Thermal Sprayed Coatings
Journal of Thermal Spray Technology
2006
Characterization of Interdigital Capacitive Strain Gauges by Direct Write Technology
Heat Transfer: Volume 3
2005
Microstructure and Electrical Characteristics of Plasma Sprayed Thick Film Mn-Co-Ni Oxide Thermistor
MRS Proceedings
2005
Low-temperature annealing effect on plasma sprayed mnzn ferrite for planar transformers of high-frequency applications
IEEE Transactions on Magnetics
2003
Analysis of Undercooling, Nucleation, Rapid Solidification, and Microstructure Formation in Thermal Spraying
Heat Transfer, Volume 5
2002
Correction of intensities for preferred orientation in neutron-diffraction data of NiTi shape-memory alloy using the generalized spherical-harmonic description
Applied Physics A: Materials Science & Processing
2002
Towards Reliable Thermal Spray Coatings: An Integrated Approach
Materials: Book of Abstracts
2000
ChemInform Abstract: Thermal Spray Processing of Nickel Aluminides
ChemInform
1998
Automated Thermal Spray Technology for Rehabilitation and Maintenance of Civil Works Infrastructure
International Thermal Spray Conference
1997
A Comprehensive Approach for Advancing Plasma Spray Processing Technology
International Thermal Spray Conference
1996
Thermal spray coatings
Metallurgical and Ceramic Protective Coatings
1996

Education

Stony Brook University

PhD., Materials Science & Engineering / 1989

Stony Brook, New York, United States of America

Banaras Hindu University

B.S., Metallurgical Engineering / 1985

Varanasi

Experience

Center for Thermal Spray Research, NSF MRSEC

Director / 2001Present

Stony Brook University

SUNY Distinguished Professor, Joint appointment with Mechanical Engineering / 2001Present

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