The Plasma Spray Process

Among the most critical spraying parameters are the relative positions of the plasma gun nozzle and the workpiece during the spray operation, and specially, the separation distance and spray angle, as well as the traversing speed at which the gun travels across the surface during spraying (Fig. 5).

Optimization of these parameters gives a prescribed microstructure. Changing one of the spray parameters can result in a weak structure, e.g., changing the distance from the plasma gun to the work piece in order to reduce or increase the porosity is not the proper way to do that. Selection of powders with the desired manufacturing morphology is the preferable way to change amount and distribution of porosities in a coating.

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