You can get by plasma spraying a fairly dense (< 2% porosity) layer of bronze powder. But therefore you need a plasma system with a high gas velocity. This can be, for example, plasma torch 100HE (http://www.progressivesurface.com/machine.php?id=49) or Axial III (http://www.mettech.com/coating-equipment/axial-III-plasma-spray-system.php).

Thank you.  The need for a higher gas velocity gun seems to make sense.  Using a standard plasma gun with radial powder injection, the coating exhibits a high degree of porosity and unmelts - hence suggesting that the particles need to have more energy in order to consolidate better upon impact (similar to an HVOF coating in terms of density).  I would assume that the low powder density g/cc is a big factor for this.