Effect of critical plasma spray parameters on the microstructure, microhardness and wear and corrosion resistance of plasma sprayed alumina coatings

► Synthesis of plasma sprayable α and γ-alumina powders without agglomeration step ► Plasma spraying alumina powders at three critical plasma spray parameters (CPSP) ► Moderate CPSP results in coatings with better wear and corrosion resistance. ► Coatings from γ-alumina powders exhibited a change in the preferred orientation.