In plasma spraying, the material is applied in what state?

• A. Atomized state
• B. Solid block form
• C. Liquid slurry
• D. Gaseous phase without solid deposition

Answer: (D)

The material used in plasma spraying is carried as atomized powder. These tiny powder particles are fed into the high-temperature plasma jet, where they melt or become semi-molten and are accelerated toward the substrate. On impact, the particles flatten and rapidly solidify, forming the coating. This approach relies on solid particles delivering material, not vapor. A solid block form would not feed correctly through the system; a liquid slurry isn’t stable or suitable in the plasma environment; and depositing from a gaseous phase would be a vapor-deposition process (not plasma spraying).