This study examines the fundamental reactions that, in the solution plasma spraying process, lead to the conversion of the precursor salts to solid material that is deposited onto the substrate. The study specifically focused on the phenomena occurring in-flight and the effect of plasma jet treatment on the mechanical and thermal treatment of the solution injected in the form of a liquid jet. The evolution of precursor droplets in the plasma flow was investigated “in situ” using a shadowgraphy technique. The morphology and structure of material deposited onto smooth stainless steel substrates during single scan experiments were characterized by SEM, GI-XRD and micro-Raman spectroscopy and were correlated to the in-flight observations, in order to evaluate the effect of the plasma-forming gas and solution solvent.

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