The integration of thermocouples into thermal spray deposits and especially into vacuum thermal spray coatings could provide temperature monitoring between the substrate and the coating or between two different coatings during the spray process and later during post treatments and service life. Thermocouples of 251µm in diameter were made using Chromel and Alumel wires. Electrical insulation was obtained using a ceramic cement. Astroloy and Copper coatings were successfully sprayed over these sensors and the temperature given by an embedded thermocouple was compared to the response of an infrared pyrometer during the spraying process.

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