Biomedical Ti-coatings were deposited on Ti-substrates by the microplasma wire spraying method. The influence of different factors of the wire spraying process on sizes of the particles produced as a result of atomisation of the wire melt by the microplasma jet, as well as the deposition efficiency were determined by using multifactorial experimental design. Linear regression models were developed, showing the effect of the most significant process parameters (current, plasma gas flow rate, wire feed speed) on formation of a jet of the spraying Ti-particles, structure and properties of the Ti-coatings. Establishing the possibility of controlling macroporosity of the Ti-coatings in microplasma wire spraying and correspondence of the Ti-coatings bond strength in tensile and shear tests to the ISO 13779-2 and ASTM C633 requirements, as well as data of the Ti-coatings “in-vivo” tests proved the efficiency of using them for manufacture of various-purpose endoprostheses (hip joint, dental, etc.).

Mathematical models for simulation of motion and heating of fine ceramic particles in plasma and laser spraying, as well as under conditions of a new technological process, i.e. hybrid laser-plasma spraying, are proposed. Trajectories, velocities and temperature fields of fine SiO 2 particles being sprayed using the argon plasma jet, CO 2 -laser beam and their combination have been calculated. It is shown that the space-time distribution of temperature in spray particles greatly depends upon the spraying method.

Microplasma spraying process provides deposition of coatings on small sizes parts and components. An investigation into the process of production and properties of microplasma coatings from bioactive ceramics (hydroxyapatite, tricalcium phosphate and fluorinoapatite) was carried out. Bioactivity of the coatings was tested in vitro by estimation of growth and differentiation of osteogenic cell.

A computer model intended for modelling of subsonic turbulent plasma jets generated by plasma spray torches, as well as for simulation of spray particles behaviour in such jets is presented. Comparison of computer modelling and measurement results showed fairly good agreement.

An important factor in the process of formation of a metal-polymer coating is the effect of a high-temperature gas jet on the "coating-substrate" system, as the jet favours penetration and spread of a polymeric material over the surface of the substrate. It is this factor that makes this form of thermal spraying radically different from spraying metallic coatings. On the other hand, excessive heating of the surface can lead to oxidation and degradation of the polymeric component. Therefore, thermal phenomena taking place during the formation of thermal sprayed metal-polymeric coatings, i.e. the level and distribution of temperatures through the thickness of a coating were analysed. Based on the results of mathematical modeling, recommendations for the thermal spraying of metal-polymeric coatings (heat source speed, spraying distance, flow rate of working gases, etc.) were developed.

In thermal spraying of metal-polymer coatings, the processes of polymers oxidation and destruction can have special features, as the temperature of heating of the filler particles can significantly exceed the temperature of destruction of the polymer binder. Hence, the need to study the features of the process of formation of thermal sprayed coatings from filled polymers and their physico-chemical, mechanical and service properties. This paper describes the influence of a filler composition and conditions of flame spraying on a structure and mechanical properties of composite polymer coatings. It is observed that addition of 5-10 vol. % of Fe-Ni-B alloy powder to low-pressure polyethylene polymer matrices, improves the wear resistance of thermal sprayed coatings 1.2-1.3 times under the conditions of gas-abrasive wear, compared to purely polymer coating, owing to the combination of the higher hardness of the coating with the high damping properties of the polymer matrix.

Addition of CaSi 2 in steel melt leads to a decrease of oxygen content, an increase of the melt flow capability, an improvement of a metal ductility and weldability. For an estimation of CaSi2 and Si additions effect in conditions of thermal spraying composite powders were produced. A base material of these powders particles is nickel, nichrom and iron. CaSi 2 and Si are additional components of the powders (3-12 wt. %). Plasma coatings produced with using of these powders exhibit high density and adhesion. The coatings structure has a high grade of microcrystallinity with a decreasing size of lamels. Oxides content in the coatings decreases with an increasing of CaSi 2 and Si content in the composite powders, moreover this effect is more essential in case of CaSi2 addition. Addition of CaSi 2 and Si to Ni-base coatings increases a microhardness from 1900-2000 MPa to 2200-2850 MPa. In case of NiCr-base coatings this increasing is from 1800-2100 MPa to 2400-3500 MPa.

Stainless steel coatings were produced by supersonic air-gas plasma spraying method. Mixture of air and natural gas was used as a plasma forming gas. Powders of 304L and 316L stainless steels were used for plasma spraying. Thickness of coatings was up to 3 mm. Coating structure was studied. Dependence of oxygen content in coatings upon particle sizes and spraying conditions was established. Investigation of electrochemical properties of coatings was carried out by potentiostatic method. Corrosion potential and corrosion rate in sea water, hydrochloric and sulphuric acid solutions were determined.