Comparison and Parametric Analysis of SPS Coatings Fabricated with Conventional and Cascaded Torches

Abstract In this study, suspension plasma spray coatings were fabricated using two different plasma torches, both equipped with a mechanical injector. A parametric study was performed to evaluate the effects of five process parameters on coating porosity: suspension mass load, spray distance, plasma power, spray step, and substrate roughness. A linear regression model of porosity was established. The model has the potential to predict the global porosity in the coating.