The Definition of Power in Plasma Spraying: Kilowatts or Powder Melting Capacity?

This study provides an objective comparison of the spraying performance of cascaded and traditional single-electrode plasma guns. Coatings with equivalent porosities were obtained using identical spray distances with similar measured particle states. The results show that cascaded plasma guns operate at higher feed rates, consume less energy and gas, and deposit coatings at lower cost per weight. They also improve arc stability and reduce variations in particle temperature.