Modern Online Process Monitoring Strategies for Thermal Spray Processes in Internal Diameter Coating Applications
Authors: Prof. Dr.-Ing. Dipl.-Wirt.Ing. Wolfgang Tillmann, Prof. Dr. Jochen Schein, Dr.-Ing. Stephan Zimmermann, Dipl.-Ing. Manuel Pinho Ferreira, Dr.-Ing. Ingor Theodor Baumann, Dipl.-Wirt.-Ing. Leif Hagen
DOI: https://doi.org/10.53192/TSB20260298
Internal coating of components using thermal spray processes such as high-velocity oxygen fuel (HVOF) spraying is becoming increasingly important. However, due to restricted accessibility and altered process conditions in internal diameter (ID) coating, it poses particular challenges for process diagnostics. The aim of this contribution is to develop suitable online diagnostics for improved process monitoring and quality assurance. Within the IGF project 22.830N, adapted measurement optics, test components with integrated viewing windows, and combined experimental and numerical approaches were developed for this purpose. The thermal profile of the coating process (flame and component) was analyzed by computational fluid dynamics simulations and pyrometer measurements, while particle properties were recorded using the SprayWatch system and high-speed cameras. In addition, acoustic analysis is investigated as a new diagnostic approach. Evaluation of acoustic signals provides additional information on process stability and disturbances, thereby extending the existing optical and thermal methods into a comprehensive monitoring concept.
Pages: 98 - 105
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