Abstract: A powder port blow-off system for a plasma spray process includes a faceplate that includes a bore therein that is co-radially aligned with a nozzle of a plasma spray gun, which emits a plasma plume. A plurality of powder feed ports are arranged circumferentially around the nozzle for injecting a flow of powder particles toward the plasma plume. A plurality of powder port blow-offs are arranged circumferentially around the nozzle in order to direct blow-off gas across the powder feed ports. The powder port blow-offs are directed across the plasma plume to create a vortex for carrying away powder particles unconsumed by the plasma plume.

Abstract: A method for the synthesis of an electrode, and the resulting article therefrom, comprising coating an active material feedstock with an additive material suitable for preventing thermal decomposition of said feedstock during thermal spray, thermal spraying the coated feedstock onto a substrate for an electrode, thereby forming a coating on the substrate, thereby providing an electrode.

Abstract: A method for the synthesis of an electrode (1), and the resulting article (1) therefrom, comprising coating an active material feedstock (3) with an additive material suitable for preventing thermal decomposition of said feedstock (3) during thermal spray, thermal spraying the coated feedstock (3) onto a substrate (2) for an electrode, thereby forming a coating on the substrate (2), thereby providing an electrode (1).