Abstract
Abstract This study assesses the effect of injector geometry on particle injection in plasma spraying. Numerical simulations show that high particle velocities can be realized with an injector that is significantly longer than the norm. In order to verify the prediction, injectors with different diameters and lengths were used to spray Al2O3 powders while measuring particle velocity at the injector outlet. Based on velocity, coating thickness, and XRD measurements, it is shown that small changes in injector geometry can have a significant influence on particle behavior without affecting phase composition. The unaltered state of the phase composition indicates that the particles did not possess enough momentum to penetrate the comparatively fast plasma jet.
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