Molten droplet temperature is a dominant factor influencing the bonding formation at the interface between splats during plasma spraying. In this study, the effect of molten droplet temperature on the interface bonding formation between nickel-base alloy splats was investigated. One novel shellcore- structured Mo-clad NiCr powder and conventional NiCr powder were used as the feedstock. Stainless steel with surface polishing was used as the substrate. The NiCrMo particle with a temperature over 2647 °C was generated by plasma spraying in comparison with that about 2167 °C for NiCr droplet. The molten droplet temperature when it impacted on the substrate surface was changed continuously by changing spray distance. The particle temperature was measured by DPV2000 and the interface bonding state was characterized by the cross-section samples of splat-substrate interface prepared by FIB. Results show that the interface bonding ratio can be increased from ~40% to 80% when the average molten droplet temperature is increased from ~2167 to 2647 °C.

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