This paper compares two approaches for monitoring in-flight particle properties during thermal spraying, one based on an industrial CCD camera, the other on a commercial diagnostic system. The camera and detector of the diagnostic tool were installed on opposite sides of a jet axis at a point where a workpiece would normally be placed for coating. Test results for a wide range of powder mixtures sprayed using different plasma and HVOF guns show good agreement between the two approaches in terms of the absolute values measured and the basic tendencies of variations in spraying parameters. A statistical evaluation of particle size, speed, and temperature is also carried out in order to determine the influence of process parameters on powder jet characteristics. Paper includes a German-language abstract.

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