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Electrical and electrochemical properties of fly ash and effect of pyrolysisAbstract. This paper presents on a study of atmospheric plasma spray parameters using fly ash as a feedstock material to spray onto the mild steel substrates. The experiments were carried out using two level fractional factorial design with four variables namely the primary and carrier gas pressures, powder feed rate and plasma power. The evaluation of response was performed on porosity by using image analysis. The results obtained show that primary gas pressure, powder feed rate and interaction primary gas pressure and carrier gas pressure are most significant factors in affecting the porosity of fly ash deposited coatings.