Newly-developed multi electrode spraying systems have improved the process stability and coating properties in air plasma spraying (APS) significantly. The new generation three-cathode torches, i.e. TriplexProTM-200/210, can be operated without significant plasma fluctuations. In previous studies a numerical model, which couples fluid dynamic, electro-magnetic and thermal relationships to investigate the flow characteristics in the torch were introduced. In this study further development of the model with respect to meshing and turbulence model will be introduced. Furthermore, free jet simulations will be conducted which use temperature and pressure profile at the outlet of the torch as inletting boundary conditions. Advanced diagnostic methods will be implemented to verify the capability of the numerical models.
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