Two new inner contours of de Laval nozzles (V70, V21) for F4 torch, which have already successfully been established for the Atmospheric Plasma Spraying (APS) are investigated for application under Vacuum Plasma Spraying conditions (VPS). Studies have been performed with regard to power efficiency, sound level and arc voltage fluctuations as well as coating quality and deposition efficiency for use of CoNiCrAlY powder as feedstock material. The results are compared to the commonly used standard VPS nozzle. CFD calculations and enthalpy probe measurements of plasma gas velocity and temperature distribution in the centreline of the supersonic plasma jets are carried out in order to get insight in the basic dependencies.

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