The correlation between particle temperature and velocity and the structure of plasma sprayed zirconia coatings is studied to determine which parameter most strongly influences the coating structure. The particle temperature and velocity are measured using an integrated optical monitoring system positioned normal to the spraying axis. The total porosity, angular crack distribution, crack size distribution and thermal diffusivity are correlated with the particle temperature and velocity. Results show that the temperature of the sprayed particles has a larger effect on the coating properties than the velocity in the conditions investigated.

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