In thermal spraying, the knowledge of process basic input parameters and their influence on the final coating properties is crucial. The optimization and reliability of atmospherically sprayed (APS) coatings, especially highly porous thermal barrier coatings (TBC), is closely linked to process understanding. This investigation aims to elucidate the correlation between the basic plasma spraying parameters (like current, plasma gas, stand-off distance, etc.) and the deduced physical dimensions like particle temperatures and velocities and the coating mechanical properties. Within this project, a large range of parameter field was chosen as long as stable plasma working conditions permitted. The influence of preparation on the microstructure analysis and data of mechanical coating measurements are shown.

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