Effect of particle size distribution width on repeatability of coating characteristics in atmospheric plasma spraying

Atmospheric plasma spraying (APS) is a widely used thermal process for producing coatings various applications. The characteristics of the produced influenced by multiple tens parameters and their complex interactions. Even when same are used, there considerable variability in coatings. poor repeatability coating can be attributed to instabilities as well relatively large measurement uncertainties characterization methods. In this study, it was investigated how particle size distribution (PSD) width affects between spray runs. It focused on four parameters: thickness, porosity, microhardness deposition efficiency (DE). First, these were evaluated. Then, effect PSD examined comparing two sets One set sprayed using powder with wide PSD; while other, sieved narrower but mean size. All other both results show that narrow improves also improving repeatability.