The scanning acoustic microscopy (SAM) technique is used for studying the character and interface quality of cold sprayed Fe coatings deposited onto notched Al-based substrates. Three notch geometries were used: a rectangular notch, a trapezoidal notch with a flat bed, and a trapezoidal notch with a cylindrical bed. Scanning electron micrographs demonstrated an increased porosity and cracks at the areas where the spraying direction was not perpendicular to the surface of the substrate. The SAM measurements were then performed on thin plates cut vertically across the notches such that the scanned area included the locations of the increased porosity and their surroundings. The resulting distributions of longitudinal wave velocities and their attenuation revealed that the affected area is more complex and the mechanical response of the coatings could be limited not only at areas of the visible porosity, but also in their vicinity.

To assess workplace exposure to nickel during thermal spraying, an air quality study was conducted at a thermal spray facility between 2007 and 2010 and 22 thermal spray operators were monitored. Results show that certain activities and operations have the potential for high exposure to nickel compounds. It is also shown that the biological agent tolerance value (BAT-value) of water-insoluble nickel compounds can be respected if specific technical, organizational, and personal-protective measures are consistently implemented.

A new technology has been introduced to measure process variables as well as to store gun-relevant data directly inside a thermal spray gun. This paper describes how this technology helps to reduce cost on the areas of process quality, maintenance and coating development. Test series have been carried out proofing reduced failure costs by detecting erroneous spray system configuration and functionality. Another section describes a cost decrease of maintenance prevention by intelligently using gun data. Additional test series show a cost reduction in parameter development in case of parameter transport to different thermal spray systems.

As the requirements placed on thermal coatings become increasingly stringent, being able to acquire more accurate data more quickly is becoming increasingly important. To achieve this, process variables must be measured close to or even inside the gun. This paper introduces a new product which measures process variables directly inside a thermal spray gun. It explains the advantages of measuring the process variables inside the gun, but also why it is important to have gun-relevant data stored on the gun itself.