Patent ID: 8080759

Claim:
A plasma spray coating system comprising: a cathode module comprising at least one cathode; an anode module; a pilot insert under potential during ignition of said plasma spray coating system to provide pilot arcing with said cathode, said pilot insert disposed down-stream of said cathode and between said cathode module and said anode module, said pilot module disposed adjacent said cathode module and having a first channel including an interior cross-sectional diameter opening Dp; and at least one electrically insulated inter-electrode insert disposed between said pilot insert and said anode module, said at least one inter-electrode insert having at least one transverse surface that is angled downstream and having a second channel including an interior cross-section diameter opening Dc, wherein said first and said second channels are axially aligned with said cathode; wherein Dp<Dc and 0.85>Dp/Dc>0.5, wherein Dc−Dp>1.5 mm; and wherein said pilot insert has a longitudinal length and said length is about 0.5-3.0 of Dc.