| Summary: | In order to study the mechanism of pulsed magnetic field in supersonic plasma spraying process, the preparation of a Ni60 coating by pulsed magnetic field (PMF)-assisted supersonic plasma spraying was studied theoretically and experimentally to characterise the flight, impact, and spread behaviours of coating powder particles as well as stacking results and thus gain valuable mechanistic insights. PMF application made the particle flight paths converge inward, the flight speed decrease, decelerated the temperature drop, improved the particle melting state, promoted impact location concentration, afforded a more uniform particle morphology, and hindered breaking and splashing to increase the hardness, bonding strength, residual compressive stress, and compactness of the deposited coating. The obtained results provide a solid basis for the study of PMF–assisted supersonic plasma spraying.
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