The current study was undertaken as part of an ongoing effort at CTSR towards development of 'Process Maps' for thermal spray coatings of molybdenum. Extensive study of the spray stream of molybdenum powders in a plasma jet was carried out. The study was undertaken for three distinct nozzle (anode) geometries and different spray conditions for each nozzle. The results demonstrate that the particle velocities and temperatures vary in an interdependent manner over a narrow range for any single nozzle. When nozzles with different geometeries are used the velocity and temperature range can be extended considerably. By estimating the residence time of particles in the plasma jet and defining a 'melting index' for the particles, a cross comparison of nozzles provides insight into the particle state achieved in each case.

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