When plasma spraying operations require high throughput, three-cathode guns may be specified due to their stationary plasma jet and elevated power characteristics, higher feeding rates, and adequate deposition efficiencies compared to one-cathode guns. A new three-anode gun system has been introduced to the market that offers a combination of high power inputs into the plasma as well as stable process conditions. These new guns feature a narrower nozzle outlet diameter compared to multi-cathode designs and they can be used with hydrogen as secondary plasma gas. Both of these characteristics result in higher plasma velocities and net powers. The conceptional designs for two such guns are discussed as well as their suitability for suspension and shrouded plasma spraying.

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