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In order to enhance understandings of the coating formation in the plasma spraying, an empirical method known as the spot spraying bead formation, was designed. This study is focused on the applicability of the proposed empirical method to explain the microstructural inhomogeneity during the process. Based on the in-flight particle diagnostics using DPV-2000, two different plasma gas compositions were chosen to evaluate the plasma gas effect on the microstructural evolution of Al2O3-TiO2 composite feedstock. A blended NiCr-Cr2O3-Ag-Ca/BaF2 feedstock was sprayed in order to examine the effects of particle parameters on the particle trajectory and the coating microstructures. Through the empirical approach, impacting particle properties and particle trajectory depending on process parameters could be directly shown and coating microstructures could be deduced from the characteristics of the spot spraying bead.

Fine and coarse alumina-titania composite particles were overlaid by allowing the particles to be deposited for a short time without moving a plasmatron [spot spraying bead]. Both the deposition efficiency and maximum deposition rate were measured at the different plasma gas composition. Considering the normalized maximum deposition rate [(maximum deposition rate)x(deposition efficiency)-1], effects of particle size and plasma gas composition on the particle segregation within a cross-section of mass flux could be estimated. Also, particle melting state according to the position within a mass flux at the moment of impact could be also estimated through the investigations of microstructure and phase composition of the spot spraying bead.

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