A method of operation of a 
plasma torch and the 
plasma apparatus to produce a hot gas 
jet stream directed towards a workpiece to be coated by first injecting a cold 
high pressure carrier gas containing a 
powder material into a cold main 
high pressure gas flow and then directing this combined 
high pressure gas flow coaxially around a 
plasma exiting from an operating 
plasma generator and converging directly into the hot plasma 
effluent, thereby mixing with the hot plasma 
effluent to form a gas 
stream with a net temperature based on the 
enthalpy of the plasma 
stream and the temperature and volume of the cold high pressure converging gas, establishing a net temperature of the gas 
stream at a temperature such that the powdered material will not melt or soften, and projecting the 
powder particles at 
high velocity onto a workpiece surface. The improvement resides in mixing a cold high pressure carrier gas with 
powder material entrained in it, with a cold 
high pressure gas flow of gas prior to mixing this combined gas flow with the plasma 
effluent which is utilized to heat the combined gas flow to an elevated temperature limited to not exceeding the 
softening point or 
melting point of the powder material. The resulting hot 
high pressure gas flow is directed through a 
supersonic nozzle to accelerate this heated gas flow to supersonic velocities, thereby providing sufficient velocity to the particles striking the workpiece to achieve a 
kinetic energy transformation into elastic deformation of the particles as they 
impact the onto the workpiece surface and forming a dense, tightly adhering cohesive 
coating. Preferably the powder material is of metals, alloys, polymers and mixtures thereof or with semiconductors or ceramics and the powder material is preferably of a particle size range exceeding 50 microns. The 
system also includes a rotating member for 
coating concave surfaces and internal bores or other such devices which can be better coated using rotation.