Plasma spraying of liquid feedstocks allows deposition of materials with novel microstructures. Due to the combination of a liquid carrier and ultrafine powders (in case of suspensions) or in-situ formation of the final material in the plasma jet (in case of solutions), preparation of ultrafine composites is possible, typically in a form of coatings on the substrates. Moreover, both suspension and solution spraying routes can be easily combined, either together or even with conventional plasma spraying of coarse dry powders, thus merging benefits of “nanometric” and “micrometric” constituents in the final composite microstructure. As a consequence, liquid feedstock plasma spraying represents an industrially-relevant deposition process with wide variability, providing coatings with properties tailored for various applications ranging from compact wear-resistant layers, porous thermal barrier coatings, bio-compatible medical coatings, catalyst carriers, fuel-cells, etc. The paper introduces several examples of such ultrafine coatings recently deposited at IPP CAS using hybrid water-stabilized plasma torch.Keywords: Plasma spraying, liquid feedstock, coatings, functionally graded materials (FGMs)
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