This paper investigates the influence of plasma variations on the microstructure and application rate of aluminum coatings and compares layers obtained using parameters that result in the same particle properties but different changes in stress. Layers produced in the less stable plasma state were found to be more porous and contained a significantly higher number of unfused particles than those produced under relatively stable conditions. These differences are due to the physical properties of the particle beam as revealed by laser illumination. Paper includes a German-language abstract.

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