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The effect of various small-particle plasma spray powder injection parameters on the in situ particle position, velocity, and temperature is measured for yttria-stabilized zirconia and yttrium-aluminum-garnet powder. Using full-factorial experiments and multiple regression analysis, carrier gas flow, injector angle, and powder feeder disc speed were found to significantly affect the particle properties. Temperature and velocity were inversely related; on average, the cooler particles traveled faster. These properties also correlated to the particle position in the flame, where particles above the centerline of the flame traveled faster. The trends are discussed on the basis of residence time in the flame, as well as in terms of particle size segregation effects. Coating density and splat geometry reflect the temperature and velocity differences between the runs. Slower, hotter particles possessed more intrasplat and intersplat porosity and less splat-substrate contact area, leading to lower overall coating density.

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