This paper shows how in-flight particle diagnostics can be used to optimize parameter sets for new layer materials and to detect drift in the control of thermal spraying lines. It describes the equipment and methods used to measure the temperature, velocity, and diameter of spray particles in a plasma jet and explains how torch current, plasma gas composition, carrier and total gas flow, and stand-off distance are varied according to a statistical design plan to determine their effect. The results are presented in the form of process maps and data plots, from which several conclusions are drawn. Paper includes a German-language abstract.

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