NOVELTY - The manufacturing method involves providing substrate (160) having exposed first surface (190), disposing powder (180) having particles to exposed surface of substrate to form particle layer, creating flame (120) near or on first electrode so that high voltage current can pass from flame, through particle layer and substrate to second electrode connected to substrate, electrically energizing electrodes causing current flow through flame and particle layer, and consolidating or sintering particles to number of degrees on substrate in current flow area.    USE - Manufacturing method for coating, such as ceramic coating used in e.g. thermal barrier coating (TBC) for gas turbine engine. Can also be used on metals, including fuel cells, battery-electrode coatings, wire-insulation coatings, wear and abrasion surfaces, cookware, engines, exhaust shields, power plants of various types, biomedical implants, and aerospace applications.    ADVANTAGE - Enables lower cost and non-contact method of electric field sintering powder coatings, shortens sintering times, enables applications not suitable for vacuum chambers, is amenable to large and complex shapes, and has the potential to control the degree of sintering and grain growth through judicious selection of process parameters. The plasma is a composite of both flame plasma and electric arc plasma, which enables a lower current flow than is required to sustain a pure electric arc so that the right amount of energy to properly sinter, without damaging the powder coating, can be achieved more readily. The flame helps to bring the coating material up to a temperature where electric current sintering can be effective. While the flame does control the zone of the electric arc plasma, if there are holes or cracks in the coating, the arc will try to move to these areas of a lower resistance path and will jump over or move quickly by areas where the coating has significantly higher resistance.    DETAILED DESCRIPTION - The substrate is metal, semiconductor, or composite containing metal or semiconductor. The particles are ceramic, metalloid, or semiconductor. The particles have electrical conductivity less than that of the substrate. The flame assembly is electrically energized by alternating current (AC) or direct current (DC) power supply and creates electrical plasma in the flame. INDEPENDENT CLAIMS are also included for the following:    (1) a device for sintering powder coating on substrate; and    (2) a process for sintering coating on substrate with combination of fame and electric current.    DESCRIPTION OF DRAWING(S) - The drawing shows a schematic diagram of a device for sintering coating on substrate.    Torch (100)    Flame (120)    Substrate (160)    Powder (180)    First surface (190)