Anilox rolls require dense, adherent chromium oxide coatings capable of the highest quality microfinishing and laser engraving. Process economy and high deposition rate are also essential. Increasingly, anilox roll job shops are spraying such coatings using a high power plasma system, prompting this detailed investigation of processes, powders, and finishing. This paper evaluates how the material and the process influence the finished texture and engraving quality. Criteria for a successful coating are defined. The effects of plasma process, powder type, and coating microstructure on finish and engraveability mc analyzed in detail and practical recommendations are made. The test matrix includes high power and conventional plasma spray systems, three commercial chromium oxide powders used in anilox roll spraying, and three commonly used finishing methods.

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