In a special torch, a plasma jet will be created for example by the plasma gas Argon. In the plasma jet the temperature will reach almost 10,000 degrees Celsius. We can introduce a powder (sometimes liquid) into the plasma jet. Because of the high temperature the powder will melt, and propelled towards a substrate. There, the molten droplets flatten, rapidly solidify and form a deposit. The introduced powder can be made of various metals, depending on layer thickness, function of the deposit or physical properties. The range of layer thickness at plasma spraying is 20 micrometers to several millimeters, depending on the process and powder.

There are a large number of technological parameters that influence the interaction of the particles sprayed on the substrate. Parameters such as torch offset, flow rate and energy input are important. Because the plasma jet is created by a controlled flow rate of the plasma gas, flow controllers are crucial. Monitoring the pressure is important to control the system and detect an empty plasma gas cylinder. Often the system will be expanded with filters to be sure no other particulates will be involved in the plasma spraying process.

The plasma spaying process needs a high accuracy and stability of the plasma gas flow. Also the monitoring of the gas pressure is important for a good control of the plasma process. Bronkhorst High-Tech can provide mass flow controllers and pressure controllers that are suitable for this. Bronkhorst High-Tech also understands that a customized solution can be very attractive for systems like plasma spraying.