To provide a more efficient powder port blow-off system for a plasma thermal spray process with less stops during development procedure.

A powder port blow-off system 12 for a plasma spray process includes a faceplate 18 that includes a bore therein that is co-radially aligned with a nozzle 21 of a plasma spray gun 14, which emits a plasma plume 24. A plurality of powder feed ports 16A, 16B, 16C are arranged circumferentially around the nozzle for injecting a flow of powder particles toward the plasma plume 24. A plurality of powder port blow-offs 12A, 12B, 12C are arranged circumferentially around the nozzle in order to direct blow-off gas across the powder feed ports 16A, 16B, 16C. The powder port blow-offs 12A, 12B, 12C are directed across the entire part of the plasma plume 24 to create a vortex for carrying away powder particles unconsumed by the plasma plume 24.

COPYRIGHT: (C)2008,JPO&INPIT