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1-7 of 7
J. Blain
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Proceedings Papers
ITSC 2007, Thermal Spray 2007: Proceedings from the International Thermal Spray Conference, 832-836, May 14–16, 2007,
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For a decade now, industrial sensors have been commercially available to both academia and industry. In general, these sensors measure individual and/or bulk properties of the powders being sprayed. Experience has shown that normally, researchers will tend to favor sensors with high spatial resolution like the DPV 2000, because of the fundamental information they give about the plume structure. Such information is vital for proper gun design and spray parameter optimization. However, for process monitoring applications typically performed with a sensor like the AccuraSpray, it is often more convenient to measure global properties over a wider volume inside the plume. In this case, there is always a tradeoff to be made between spatial resolution and fundamental process understanding. This paper illustrates this point by comparing two optical configurations, one with high spatial resolution and another one with medium resolution. This latter configuration makes use of a cylindrical lens to expand the sensor field of view in a direction perpendicular to the spray direction. Results clearly show that with minor optical modifications such sensors can be tailored to precise industrial requirements.
Proceedings Papers
ITSC 2007, Thermal Spray 2007: Proceedings from the International Thermal Spray Conference, 860-865, May 14–16, 2007,
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Numerous efforts have been carried out over the years to improve process control in the thermal spray industry. Among those, the need for online monitoring of the thickness of the coating is unquestionable as it leads directly to better uniformity, less powder usage and increased productivity. In 2006, a new technology based on 3D profiling has been adapted to the thermal spraying environment and has shown conclusive results for online real-time monitoring of the thickness of single layers as they were being sprayed. A micron level resolution was achieved independently of the process, the powder and the thermal effects related to thermal spraying. In this paper, we present the latest results from early industrial implementations. New applications of this technology for substrate geometries with increased complexity are also investigated.
Proceedings Papers
ITSC 2006, Thermal Spray 2006: Proceedings from the International Thermal Spray Conference, 981-986, May 15–18, 2006,
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In the past ten years, significant progress has been made in the field of advanced sensors for particle and spray plume characterization. However, there are very few commercially available technologies for online characterization of the as-deposited coatings. In particular, coating thickness is one of the most important parameter to monitor and control. Current methods such as destructive tests or direct mechanical measurements can cause significant production downtime. This paper presents a novel approach that enables online, real-time and non-contact measurement of individual spray pass thickness during deposition. Micron-level resolution was achieved on various coatings and substrate materials. The precision has been shown to be independent from surface roughness or thermal expansion. Results obtained on typical HVOF and plasma sprayed coatings are presented. Finally, current fields of application, technical limitations and future developments are discussed.
Proceedings Papers
ITSC 2003, Thermal Spray 2003: Proceedings from the International Thermal Spray Conference, 1131-1138, May 5–8, 2003,
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This paper first presents some typical results that illustrate the need for closed-loop stabilization of plasma spraying processes. A strategy to identify the most efficient control actuators is then explained, followed by a description of a robust operator closed-loop feedback method. This method can be directly implemented on current commercial sensors and applied to older spraying equipment than cannot easily be interfaced to modern computers. The method is also capable of implementing tight computer-controlled closed-loop feedback on more modern equipment. A discussion of minimum sensor requirements is also given.
Proceedings Papers
ITSC 2001, Thermal Spray 2001: Proceedings from the International Thermal Spray Conference, 705-714, May 28–30, 2001,
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The Accuraspray is a new in-flight particle sensor that provides information on the average in-flight particle temperature, using two-color pyrometry, and velocity, using a cross-correlation calculation. Various aspects influencing the reliability of the sensor estimates are studied. First, the sensitivity of the temperature and velocity estimates to the positioning of the sensor with respect to the particle jet, such as the angular orientation of the fibers and the working distance to the spray plume, is evaluated. Then, the influence of the plasma radiation on the temperature measurement is estimated. This influence can be reduced significantly by filtering out the low frequency components of the pyrometric signals, which contain most of the plasma fluctuations. Finally, a lower limit in the signal-to-noise ratio (SNR), for which an acceptable temperature estimate is obtained, is evaluated. A valid velocity estimate can still be obtained with a lower SNR. All these studies were performed under various spraying conditions, including plasma spraying and HVOF, using various feedstock materials (YSZ, Al-Si, cermets).
Proceedings Papers
ITSC 2001, Thermal Spray 2001: Proceedings from the International Thermal Spray Conference, 723-726, May 28–30, 2001,
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Innovation and improvements are described which yield a 20 fold increase in the signal-to-noise level of a two fiber, twin wavelength high speed pyrometer used for in-flight particle diagnostics. Examples are given of how these developments extend the application range of the technology to low temperature processes such as flame spraying of low emissivity materials.
Proceedings Papers
ITSC2000, Thermal Spray 2000: Proceedings from the International Thermal Spray Conference, 1131-1134, May 8–11, 2000,
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Three actual applications of spray plume sensors for industrial coating operations are presented. Two of these are in the aeronautic industry and one in the automotive industry. Depending on the application, different types of sensors were used ranging from plume shape monitoring (particle trajectories) to full plume characterization including in-flight measurement of individual particle properties. In each case, the process monitoring scheme developed depended on the manufacturer's requirements as well as the nature of the information provided by the sensor. The significant differences in usage and working conditions compared to an R&D environment are examined. Advantages and drawbacks in each of the three situations are detailed. A tentative forecast of coming developments in this field is also given.