In this study, two particle-tracking velocimetry systems, the Oseir HiWatch HR2 and the Oseir HiWatch CS2 were tested. The particle-sizing velocimetry results were then compared with corresponding particle characteristics obtained using a Tecnar Cold Spray Meter and a Tecnar Accuraspray 4.0 unit. In addition, particle size distributions measured by laser diffraction were included for validation.

The aim of this study is to develop a solid shroud to minimize in-flight oxidation using the particle swarm optimization (PSO) algorithm. Additionally, the shroud is specially designed to use air as a cooling medium instead of water and is made from common stainless steel to help reduce equipment and process costs.

In this study, suspension plasma spray coatings were fabricated using two different plasma torches, both equipped with a mechanical injector. A parametric study was performed to evaluate the effects of five process parameters on coating porosity: suspension mass load, spray distance, plasma power, spray step, and substrate roughness. A linear regression model of porosity was established. The model has the potential to predict the global porosity in the coating.

This paper presents the AccurasprayHub, a centralized data platform designed to harmonize booth parameters, in-situ plume measurements, maintenance schedules, and coating quality evaluations. By combining domain expertise with advanced analytics, including initial steps toward machine learning, the AccurasprayHub establishes robust datasets, identifies stable process windows, and provides proactive insights for process improvements.

In this study, an internal powder injection was employed with a modified anode nozzle. The effects of the anode geometry and spray particle size on spray particle temperature were investigated. Moreover, the effect of spray particle temperature on the in-situ in-flight deoxidization and intersplat bonding formation were examined with both boron and carbon deoxidizers.