Deposition efficiency is an important metric for thermal spraying, but it can be difficult to measure in some cases. In this study, a volume-based deposition factor is developed that can be used to estimate deposition efficiency simply by evaluating process parameters, coating thickness, and porosity. Coating thickness or thickness per pass is measured from the sample and parameters like feed rate, step size, and surface speed are taken into account. The correlation to deposition efficiency is demonstrated for various plasma and HVOF processes using powder and suspension feedstock materials. An example is also given showing how the method can be used to evaluate older data sets collected without regard to deposition efficiency.

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