Very low pressure plasma spraying (LPPS) is the objective of numerous studies for the past years. However, numerical simulations and experiments revealed some difficulties such as the presence of successive expansions and constrictions of the plasma jet that has an influence on the deposition efficiency and on the coating structure. Optimization of the plasma gun is thus required and the use of bell-contoured De Laval nozzle extensions seems particularly promising. In this paper, new developments concerning the use of an in-house bell-contoured nozzle extension are presented and both numerical calculations and experiments were performed.

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