Plasma spray torches for spraying internal diameters have typically been limited to 40 kW in the past. A new internal plasma spray torch has been developed with an operational power limit above 90 kW. This high power torch was primarily developed to decrease the spray time required to apply coatings to large inside diameters such as land based gas turbine components. This paper explores the factors effecting the operation of this torch as well as the functional limits of its operation. The factors investigated are gas flow, gas ratios, current, voltage, water flow, and water temperature. Thermal efficiency and plasma enthalpy are presented.

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