A recently developed air plasma spray (APS) process and a torch based on the combined wall and gas stabilizations of plasma (C+Plasma) has demonstrated extremely wide operating window and capability to efficiently generate both argon and nitrogen based plasmas including high enthalpy N2- H2 ones. The present paper aims to describe new areas of the extended C+Plasma operating window, in which a significant increase in the APS sprayed coating quality and process efficiency should be expected. The paper includes a brief analysis of properties of different plasmas as well as specifics of coating formation. Analysis showed that with the high enthalpy N2-H2 plasmas a significantly higher heat transfer potential and higher flexibility in controlling the particle acceleration can be achieved than with the argon based plasmas. Consequently, C+Plasma can enable better treatment of sprayed particles, which results in better deposit efficiency and improved coating properties.

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