This paper examines an extended, digital CCD camera under real production conditions during plasma spraying for three visualization modes. They are beam visualization (real recording of the beam structure and development in different spatial and temporal orders of magnitude); particle-substrate interaction (particle adhesion, spraying of the particles), visualization of the zone near the substrate to show the rebound of powder; and time behavior of the layer growth as well as quantitative determination of the layer thickness in real time. Zirconium dioxide- and aluminum oxide-based ceramics are examined as typical powder systems. The developed diagnostic system is successfully tested for different types of industrial processes: plasma spraying, HVOF, and wire spraying. Wide range of powder materials and well-known spraying equipment are used in experiments. Paper includes a German-language abstract.

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