Abstract: An improved segmented anode plasma generator apparatus and method. A combustion mixture of a hydrocarbon and air is injected into the plasma chamber along the direction of the plasma vortex, causing the plasma arc attachment to the anode to be in the diffusion attachment mode, where the plasma arc attaches to the anode surface over a large area, thereby substantially reducing the anode erosion rate. An innovative design of the exit nozzle then reduces the rotational component of the plasma's exit velocity to maximize the axial component of the velocity. By modulating the plasma arc current with very sharp plasma arc current pulses at a frequency related to the dwell time of the spray particles in the plasma, multiple sequential plasma shock waves which disintegrate the spray particles and accelerate them toward the target substrate.