Three kinds of nanostructured alumina coatings were prepared by air plasma spraying. As-sprayed coatings were characterized by SEM and XRD. Their surface roughness, porosity and microhardness were also examined. Results indicated that the smaller the size of the starting powders, the better the properties of the coating. The differences in the phase composition of the as-sprayed coatings could be used to explain the differences observed in coating properties.

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