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The suspension plasma spraying process is investigated by using shadow imaging techniques to appreciate the different trajectories of the liquid jet interacting with a DC highenergy plasma flow. Then, the modelling of different liquid injections (isolated droplet, train of droplets and continuous jet) helps to determine which injection type must be preferred. From that, coating depositions have been carried out with yttria zirconia suspension. Trajectory deviations at impact have been measured depending on the injection pressure and injection location. Coatings have been realized under the same operating investigations and their microstructures and mechanical properties have been characterized.

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