This paper evaluates the performance of a new single-cathode cascaded arc spray gun developed for low-pressure plasma spraying (LPPS). It describes key design features, explaining how they contribute to arc and voltage stability, improved thermal efficiency, higher throughput, and extended equipment life. It assesses the effect of nozzle geometry on spray spot morphology and examines the microstructure of CoNiCrAlY and YSZ coatings deposited on different substrates, including a turbine blade, using the new gun. Cross-sectional images show the uniformity of the CoNiCrAlY coatings in different locations on the turbine blade, including platform, fillet, and airfoil surface.

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