The National Aeronautics and Space Administration's (NASA's) PS304 coating is a plasma spray deposited tribological coating with feedstock composed of NiCr, Cr2O3, Ag and BaF2-CaF2, powders. The effects of rounded BaF2-CaF2, particles on the gravity-fed flow characteristics of PS304 feedstock have been investigated. The BaF2-CaF2, powder was fabricated by water atomization using four sets of process parameters. Each of these powders was then characterized by microscopy and classified by screening to obtain 45-106 mu m particles and added incrementally from 0-10 wt.% to the other constituents of the PS304 feedstock, namely nichrome, chromia and silver powders. The relationship between feedstock flow rate, measured with the Hall flowmeter, and concentration of fluorides was found to be linear in each case. The slopes of the lines were between those of the linear relationships previously reported using angular and spherical fluorides and were closer to the relationship predicted using the rule of mixtures. The results offer a fluoride fabrication technique potentially more cost-effective than gas atomization processes or traditional comminution processes. (c) 2005 Elsevier B.V. All rights reserved.