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Metallurgy Division Publications - NISTIR 6776

Thermal Spray Process Reliability:
Sensors and Diagnostics
Summary of a Workshop Held at
National Institute of Standards and Technology


This report covers the second workshop on Thermal Spray (TS) coatings sponsored by the NIST Metallurgy Division. The first of these workshops, held in November, 1998, was documented in NISTIR 6460. The objectives of this current workshop included the presentation of NIST work on thermal spray sensors and diagnostics, as well as exploring the possibilities for collaborations with U.S. industry. Attendance from outside NIST was approximately 35, of whom approximately 15 could be classified as thermal spray producers and users and 20 as the thermal spray diagnostics community including instrument makers, universities, and national laboratories.

The workshop participants expressed several needs and concerns regarding the use of sensors and process measurement technology. A coatings properties database of materials characterization, mechanical properties, and statistical analysis needs to be established. New technology for deposit and substrate property measurements is needed, especially sensors to measure deposit thickness and techniques to measure residual stresses in thick deposits. There are questions concerning the calibration of non-contact temperature sensors, specifically as to how variations in material properties (e.g., particle shape, oxidation, etc.) will affect emissivity. Simple, reliable, rugged sensors are required for industrial environments. The research community must show a correlation of improved sensor performance and accuracy to improved product performance.

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