Some think that physicalism developed from materialism in line with increasingly sophisticated physics: not everything described by physics is 'material' - e.g.: gravity. Historically, I think 'physicalism' was coined by the Vienna Circle - more info here: https://plato.stanford.edu/entries/physicalism/
But the conventional view is that the terms physicalism and materialism are basically interchangeable, and that's good enough for me on a hot Melbourne afternoon.
And yes, some people are very attached to their ideas. Dualism is a dirty word in much of science. But people are coming around - David Chalmers (another ANU philosopher) is a great ambassador for dualism and panpsychism.
RE: Is there more to consciousnesses than just physics?