The integrity and properties of ceramic coatings produced by atmospheric plasma spraying are highly controlled by the splat morphology and splat interconnection. In this study, the influence of selected parameters (spray angle, surface velocity of the spray gun, and substrate temperature) on splat morphology and coating microstructure was investigated. A favorite set of spray gun parameters, of which their effects on splat morphology and coating microstructure have been verified by previous experiments, were used to conduct the experiments for the present work. It was found that depositing fully molten particles on a hot substrate increases the fraction of disk-like splats by about 60% at the expense of the fraction of irregular splats. Preheating the substrate also increases the pore count and level of coating porosity, while it does not influence the density of segmentation cracks. In contrast, the surface velocity of the spray gun does not affect the splat morphology while a slow speed decreases the coating porosity and plays a significant role in generating segmentation cracks. Shifting the spray angle by 15° distorts up to 20% of disk-like splats and slightly decreases the porosity level. However, changing the spray angle does not affect the generation of segmentation cracks.

大气等离子喷涂生产的陶瓷涂层的完整性和性能受到splat形态和splat互连的高度控制。在这项研究中，研究了所选参数（喷涂角度，喷枪表面速度和基材温度）对喷溅形态和涂层微观结构的影响。一组最喜欢的喷枪参数已通过先前的实验得到验证，其中的参数对喷溅形态和涂层微观结构的影响已用于进行本工作的实验。已经发现，将完全熔融的颗粒沉积在热的基材上会使盘状碎片的比例增加约60％，但以不规则碎片的比例为代价。预热基材还会增加孔数和涂层孔隙率，但它不会影响分段裂纹的密度。相反，喷枪的表面速度不影响喷溅形态，而慢速则可降低涂层孔隙率，并在产生分段裂纹方面发挥重要作用。将喷雾角度偏移15°，最多可变形20％的盘状碎片，并略微降低了孔隙度。但是，改变喷射角度不会影响分段裂纹的产生。