Very low pressure plasma sprayed alumina and yttria-stabilized zirconia thin dense coatings using a modified transferred arc plasma torch

► A transferred arc nozzle was designed and made to improve low-energy plasma spray torch under very low pressure condition. ► The Al2O3 and YSZ thin dense ceramic coatings were successfully deposited by such transferred arc nozzle. ► The transferred arc nozzle effects and the electron temperature on the plasma jet were evaluated. ► The transferred arc sprayed coatings exhibited better properties.