Thermal Spray Coating Microstructures
 Combustion Spray Coarse 80/20 NiCr Powder |  Combustion Spray Fine 80/20 NiCr Powder |
 Plasma Spray Coarse 80/20 NiCr Powder |  Plasma Spray Fine 80/20 NiCr Powder |
Combustion Spray Coarse 80/20 NiCr Powder | Combustion Spray Fine 80/20 NiCr Powder |
Plasma Spray Coarse 80/20 NiCr Powder | Plasma Spray Fine 80/20 NiCr Powder |
Plasma sprayed coatings generally have finer, denser microstructures with less oxide inclusions than combustion powder sprayed coatings. Plasma provides rapid heating, low particle flight time, more inert flame and higher velocity than combustion flame.
Generally, coarse powders produce a coarser and more open structured coatings with less oxidation than fine powders. This is mainly due to the differences in surface area of the powder particles exposed in the flame.
