| Abstract Scope |
Reactive plasma spraying (RPS) is an underutilized technology for in-situ formation of thick ceramic coatings relevant to energy-related industrial applications, including hydrogen permeation barriers. While conventional thin film deposition techniques produce dense nitride films, they are limited in scalability. RPS enables deposition of thicker coatings, but optimal processing conditions for controlling phase composition and microstructural density are not clearly defined. This study established a data-driven predictive framework based on Principal Component Analysis to correlate input RPS processing conditions to output TiN microstructural characteristics and properties. Parameters investigated include variations in powder feedstock, primary and secondary gas composition, feedstock flow rate, and spray distance. Deposition rate and porosity are quantified using light optical microscopy, phase fractions of TiN, TiO2, and Ti using X-ray diffraction, and hardness via microhardness indentation. Results demonstrate that deposition behavior is predominantly governed by spray distance, while powder feed rate strongly influences TiN phase stability. |