NOVELTY - Production (M1) of a material involves: injecting precursor solution droplets into a thermal spray flame where a first portion of the precursor solution droplets are injected into a hot zone of the flame and a second portion of the precursor solution droplets are injected into a cool zone of the flame; fragmenting the droplets of the first portion to form reduced size droplets and pyrolizing the reduced size droplets, followed by depositing the partially melted pyrolized particles, fragmenting and depositing the non liquid material on the substrate steps.    USE - For the production of material used in structural preform, layered material, graded material or composite material; electrolyte layer; in a thick metal oxide coating; anode layer and in a coating disposed upon a substrate; in bulk structural material (all claimed).    ADVANTAGE - The method is highly efficient and cost-effective. The produced material exhibit three dimensional porosity of 1-50 vol.%, and the pores may be micrometer sized (1-50 mu m), submicron sized (0.1-1 mu m) or nanometer sized (up to 100 nm); optionally have vertical cracks that vary in length of 0.5-1 times the thickness of the material. The material can be employed as coating over a large thickness of 1 mu m to over 5 mm or as a structural preform.    DETAILED DESCRIPTION - Production (M1) of a material involves: injecting precursor solution droplets into a thermal spray flame where a first portion of the precursor solution droplets are injected into a hot zone of the flame and a second portion of the precursor solution droplets are injected into a cool zone of the flame; fragmenting the droplets of the first portion to form reduced size droplets and pyrolizing the reduced size droplets to form pyrolized particles in the hot zone; at least partially melting the pyrolized particles in the hot zone; depositing the at least partially melted pyrolized particles on a substrate; fragmenting at least part of the second portion of precursor solution droplets to form smaller droplets and forming non-liquid material from the smaller droplets; and depositing the non liquid material on the substrate. INDEPENDENT CLAIMS are included for the following:    (1) a structural preform, layered material, graded material or composite material comprising the material, where the precursor solution droplets are injected using a piezo electric crystal induced liquid injector;    (2) an electrolyte layer comprising splats having an average diameter of less than or equal to 2 mu m; thickness of less than 200 mu m; and porosity less than 5 vol.%;    (3) a thick metal oxide coating comprising splats having an average diameter of less than or equal to 2 mu m; thickness of 500-5000 mu m; and porosity of 15-40 vol.%;    (4) an anode layer comprising splats having an average diameter of less than or equal to 2 mu m; thickness of 20-200 mu m; and porosity of 15-50 vol.%;    (5) a coating disposed upon a substrate and comprising at least one interpass boundary, where no inter pass boundaries are present within 50 mu m of an interface between the substrate and the coating; and    (6) a bulk structural material comprising splats having an average diameter of less than or equal to 2 mu m where 80-95% of the splats are splats having an average diameter of less than or equal to 2 mu m.