The objective of this study is to increase the deposition rate in the plasma-spray manufacturing of thermal barrier coatings without altering the quality of the coatings. The experimental part involves the measurement of in-flight particle characteristics and analysis of coatings properties when varying the hydrogen content of the plasma-forming gas, the torch nozzle diameter and the powder feed rate. The experimental results of particle measurements are discussed in the light of the gas flow fields projected by a 3-D model of the plasma spray process.

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