This paper focuses on a low-cost diagnostic system for real-time monitoring of particle-inflight diameters, velocities, and temperatures. This system is based on CCD image sensors, which show high sensitivity in the near infrared range. An original software package for calibration, treatment of the gray powder jet, and statistical analysis of the particle parameters is the essential part of this system. The diagnostic system is tested under industrial conditions for various spraying processes: plasma spraying, flame spraying, HVOF spraying, and arc spraying. The diagnostic system shows a high level of suitability: 10 gm particle size detection limit, detectable temperature ranges from 1200 to 3500 deg C, and 900 m/s maximum particle speed. Paper includes a German-language abstract.

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