Reactive plasma spraying (RPS) is a promising process to fabricate composite coatings with in-situ formed thermodynamically stable phases. However, the coating quality strongly depends on spray parameters therefore on-line measurement of in-flight particle characteristics can provide a unique tool for optimizing the coating properties and process conditions. In the present study, mechanically alloyed Al-Si and SiO{sub}2 powder was deposited onto an aluminum substrate by using atmospheric plasma spraying (APS). The effect of spray parameters on in-situ reactions and in-flight particle characteristics were investigated. The results showed that, alumina is formed through the in-situ reaction between aluminum and silica. Also, it has been observed that particle characteristics strongly depend on spray parameters therefore monitoring particle behavior is essential for optimizing spray parameters in reactive plasma spraying.
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