Development of coatings using the TriplexPro 200 plasma gun has provided an ideal means for implementing process maps due to the large operating window in terms of particle velocity and particle temperature, as well as the flexibility to use multiple plasma gasses to tailor the coating process. Process mapping enables tracking of coating characteristics, such as hardness, and relating those characteristics to the conditions of the particle that are induced upon the particle by the process parameters. Work performed to date has provided new insights into conditions of the powder particle that result in specific characteristics in the coating. An example is the ability to determine the critical particle energy state that affects coating stress. This work affords an understanding of general theory behind coating characteristics that result from the conditions of the particle. This paper describes the parameter impact in controlling coating stresses and determining optimum particle conditions to produce a desired, or set of desired, coating characteristics.

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