Conventional plasma spraying processes normally use a 10-100 micrometre sized feed stock to form the coating. If the solid particles traditionally used as a feedstock are replaced by a stream of droplets containing stabilized submicron ceramic suspension, further reduction in the grain size can be obtained. This may lead to superior properties. A previous study showed that by using a direct continuous ink jet printer it is possible to produce a stream of monosized, equi-spaced ceramic drops, which could be injected into the conventionally produced plasma flame. This technique significantly reduced the size of the splats produced. This paper investigates the effect of the plasma condition as well as the substrate temperature upon the splats formed in an attempt to optimize the process for coating formation. Paper includes a German-language abstract.

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