Dry-ice blasting, as an environmental-friendly method, was used during atmospheric plasma spraying for improving coating properties. This process is believed to be capable to reduce the porosity and the oxide of the coating and to increase the deposition efficiency, etc. Considering dry-ice pellets are carried and accelerated by compressed air through a convergent-divergent nozzle, the computational fluid dynamic (CFD) approach was firstly employed in this study to evaluate the effects of nozzle geometry, accelerating gas conditions as well as properties of pellets, on the pellet velocity variation and further to optimize the process. Moreover, the experiment with a steel powder was then carried out and the results indicate that a denser coating with a lower content of oxide can be achieved with the application of dry-ice blasting during the plasma spraying.

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