Abstract Studies on atmospheric plasma spraying have generally focused on the influence primary parameters such as gas flows and plasma current. However, the APS process is also influenced by a large number of disturbance variables including electrode wear, cooling system irregularities, and disruptions in powder injection. This study investigates both the cause and effect of each of these factors in the context of aluminum oxide spraying. Numerous measurements are made showing how electrode wear, cooling fluctuations, flow measurement inaccuracy, and variations in powder feed rates affect in-flight particle characteristics, deposition efficiency, and layer thickness. Paper includes a German-language abstract.