Processes for forming exoergic structures with the use of a plasma and for producing dense refractory bodies of arbitrary shape therefrom

Plasma spraying methods of forming exoergic structures and coatings, as well as exoergic structures produced by such methods, are presented. The methods include the plasma spraying of reactive exoergic materials that are capable of sustaining a combustion synthesis reaction onto a flat substrate or into molds of arbitrary shape and igniting the plasma sprayed materials, either under an inert gas pressure or not, to form refractory materials of varying densities and of varying shapes