In plasma spraying, an anode and a tungsten cathode are used High frequency ignited an arc. At the Plasma spraying will the flowing through between the electrodes Gas (argon, helium, hydrogen, nitrogen or mixtures) ionizes so that a several centimeters long plasma beam is created. The necessary process energy of plasma spraying results from the dissociation or the ionization of the gas or gas mixture flowing past the arc. Here becomes a highly heated (up to 20.000 ° C), electrically conductive gas (plasma jet) positive ions and electrons. In this generated plasma jet is powder (usual grain size distribution: 5 - 120 μm, with certain devices a grain size of up to down to 100 nm possible) due to the high plasma temperature is melted. The plasma stream breaks at Plasma spraying the powder particles and hurls them the surface to be coated. The plasma coating at Plasma spraying takes place both in normal Atmosphere as well as under a protective gas atmosphere (argon).
Furthermore, the plasma spraying carried out in a vacuum or under water. For the layer quality one Plasma sprayed surface are the speed, temperature as well as the Composition of the plasma gas of importance. The process of plasma spraying is extremely loud and therefore only in a soundproof booth possible or sensible and is usually only carried out automatically.