This paper examines ways to control the porosity of thermally sprayed deposits. All spraying was done with a water-stabilized plasma system using different combinations of alumina, zircon, Ni, and Al powders. Sandwiched structures with alternating ceramic and metal layers were sprayed as were thick deposits consisting of metal and ceramic mixtures. Porosity was characterized by methods such as gas permeability, water immersion, MIP, SEM, and SANS. In addition, several post-processing methods were tested to determine their effect on porosity volume. For example, removing metallic phases by leaching or by annealing at temperatures above the melting point was found to effectively increase porosity, while the use of sealing materials proved effective at reducing porosity. Another method tested was calcination, which resulted in an increase or decrease of porosity depending on the deposit's chemistry and annealing conditions.

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