The peculiar microstructure of plasma-sprayed coatings affects their physical properties. Many of these properties are, to a great extent, dominated by the influence of the spraying process on in-flight particle parameters. In order to improve the quality of plasma-sprayed coatings and to enhance the efficiency of plasma spray deposition, a wide range of anode nozzles have been developed for air plasma torches. The objective of this work is to investigate the influence of two convergent-divergent nozzle designs on plasma-sprayed YSZ particles at impact and the permeability, porosity, and microstructure of the resulting coatings.

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