Chemical vapor deposition methods for making powders and coatings, and coatings made using these methods

A method of forming a material, said method comprising:

• (a) providing at least one energy derived from a chemical reaction(s), said at least one energy source being the predominant source of energy for said method;
• (b) providing a liquid precursor material;
• (c) feeding a liquid precursor material into a localized environment of the at least one energy source under conditions that said energy source causes combustion of at least one component of said precursor material to produce combustion;
• (d) directing the combustion products along a first path;
• and
• (e) providing at least one source of pressure differential and applying the at least one source of pressure differential to the localized environment of the at least one energy source, such that the localized environment is selectively changed to redirect the combustion products from the first path to a redirected path at an angle relative to said first path, to thereby cause the combustion products to contact a surface and form at least part of the material.

A method of forming a material, said method comprising:

• (a) providing at least one energy source derived from a chemical reaction(s), said at least one energy source being the predominant source of energy for said method;
• (b) feeding a precursor material into a localized environment of the at least one energy source under conditions that said energy source causes combustion of at least one component of said precursor material to produce combustion products,;
• (c) directing the combustion products along a first path;
• and
• (d) providing at least one source of pressure differential and applying the at least one source of pressure differential to the localized environment of the at least one energy source, such tat the localized environment is selectively changed to redirect the combustion products from the first path to a redirected path at an angle relative to said first path, to thereby cause the gasses combustion products to contact a surface and form at least part of the material in an atmospheric environment.

A method of forming a material, said method comprising:

• (a) providing at least one energy source derived from a chemical reaction(s), said at least one energy source being the predominant source of energy for said method;
• (b) feeding a precursor material within gasses, the gasses including liquid that is at least partially vaporized, into a localized environment of the at least one energy source, to allow the at least one energy source to cause combustion of the precursor material and/or the gasses and thereby produce combustion products;
• (c) directing the combustion products along a first path;
• and
• (d) providing at least one source of pressure differential and applying the at least one source of pressure differential to the localized environment of the at least one energy source, such that the localized environment is selectively changed to redirect the combustion products from the first path to a redirected path at an angle relative to said first path, to thereby cause the combustion products to contact a surface and form at least part of the material.

A method of forming a material, said method comprising:

• (a) providing at least one combustion source derived from a chemical reaction(s), said at least one energy source being the predominant source of energy for said method;
• (b) feeding a precursor material into a localized environment of the at least one combustion source, to allow the at least one combustion source to activate the precursor material within gasses and thereby produce combustion products;
• (c) directing the combustion products along a first path;
• and
• (d) providing at least one source of pressure differential and applying the at least one source of pressure differential to the localized environment of the at least one combustion source, such that the localized environment is selectively changed to redirect the combustion products from the first path to a redirected path at an angle relative to said first path, to thereby cause the combustion products to contact a surface and form at least part of the material.