This study compares the performance of different measurement methods for characterizing particles during thermal spraying. The accuracy of double-point and single-point measurements is assessed in the context of HVOF and suspension plasma spraying (SPS) where in-flight particle temperature and velocity are recorded for different powders and suspensions. The results are evaluated by analyzing splats and correlating their size and shape to in-flight particle temperature measurements. It is shown that particle diagnostic systems based on single-point measurements are well suited for SPS and HVOF processes.

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