Plasma lineation electrode

A plasma spray device comprising:

• a throat region for receiving a non-linear flow of a plasma, the throat region having an end surface and an axial bore, the axial bore formed within the throat region in a direction substantially along a longitudinal axis of the throat region, the axial bore having a plurality of grooves, at least a portion of the plurality of grooves formed in a direction substantially along the longitudinal axis of the throat region, the axial bore at the end surface for ejecting a plasma stream,
• wherein the plasma stream has a flow that is lineated by the plurality of grooves before the plasma stream is ejected from the axial bore.

An electrode for a plasma spray device, the electrode comprising:

• a plasma chamber region;
• and
• a throat region for receiving a non-linear flow of a plasma from the plasma chamber region, the throat region being coupled to the plasma chamber region, the throat region having an end surface and an axial bore, the axial bore formed substantially along a longitudinal axis of the throat region, the axial bore for ejecting a plasma stream, the axial bore having at least a cross-sectional shape for lineating a flow of the plasma stream before the plasma stream exits the axial bore.