Tuning porous surface coatings using a plasma spray torch

A system and method are provided to create porous surface coatings. In use, a method is included for receiving, at a plasma spray torch, inputs comprising metallic particles and carbon particles, using the plasma spray torch to cause in-situ nucleation of the inputs to synthesize carbon-containing composite materials, and flowing the synthesized carbon-containing composite materials onto a substrate. Some or all of the synthesized carbon-containing composite materials may include a surface layer and/or a bonding layer. Additionally, the method may include tuning the inputs based on tuning characteristics, the tuning characteristics including one or more of: porosity, heat transfer, or resistance to corrosion. Further, the method may include tuning the inputs to optimize temperature redistribution across a surface layer of some or all of the synthesized carbon-containing composite materials.