Advanced diagnostics and modeling of spray processes

The thermal spray process features complex gas-particle interactions that include significant time-dependent variations and distributions in the characteristics of the particles incident upon the substrate. These variations limit the performance of the process in two ways; first, the inability to maintain a narrow operating window often results in coatings that do not meet specifications and must be reworked; and the complexity of the process requires significant development time for new coatings and applications. Ultimately, the science-based approach will lead to intelligent, real-time sensor- and model-based controls that will provide designers with the tools necessary to engineer specific coating features and ensure the consistent production.