Contamination is defined broadly as any material, substance or energy which adversely affects the function of the product. One type of energy contaminant is heat, or thermal contamination. Thermal contamination is a component of many manufacturing processes such as metal forming, molding, stamping, machining, and precision abrasive grinding, as well as thermal spray coating operations. Thermal spray coating processes include dual arc plasma and high velocity oxygen combustion spray processes. In both of these processes, metallic particles are melted and projected at a target metallic substrate surface. During operation, the target substrate surface temperature rapidly increases and if not controlled will impact molten particle splat geometry and adhesion. In this regard, managing surface temperature is a very important process step for ensuring uniform coating thicknesses and good adhesion.