A method for creation of a process window for on-line monitoring and controlling of the particle velocity and temperature during plasma spraying in order to enable desired coating microstructure is presented. The desired coating is specified by determination of the ranges within which the different microstructure features and the powder deposition efficiency are allowed to vary. Multiple linear regression models, relating the particle velocity and particle temperature to the coating criterions is utilized to successively delimit the particle velocity and temperature ranges. This results in a process window, giving the limits within which the particle velocity and temperature are allowed to vary in order for the desired coating to be produced.

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