Novel thermal spray technologies must be thoroughly tested before they can replace the existing processes. In order to reproduce the properties of the accepted coatings, numerous test pieces must be sprayed and characterized by many different combinations of the available spray parameters. The method is time-consuming and often not very efficient. In this paper, a different approach is considered, whereby the state of the sprayed particles is characterized during the flight. The main objective is to examine the possibility to spray particles with similar in-flight characteristics with two different plasma guns in order to spray similar coatings with both guns. It is observed that the SM-F100 plasma gun can produce similar yttria stabilized zirconia particle jets as those sprayed with the F4-MB gun with 50% less electric power. Paper includes a German-language abstract.

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