Process and quality control with thermal spray diagnostics

HCAT April 1.-2. 2003 - San Diego, CA by Mr. Ismo Lindn President Oseir Ltd.
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Diagnosing Thermal Spray

WHY ? WHERE & WHAT ? WHOW ?

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Diagnosing Thermal Spray WHY ?

Higher quality of thermally sprayed parts Better coatings competitive edge Better reproducibility - yield Less coating defects - yield ================================= Cost savings & Customer satisfaction =================================
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Measurement Is the Basis of Quality

Quality Control Measure
- through control

- through measurement

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For high quality process you need to:

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know what really happens in the process understand why something happens develop understanding how to achieve the best quality for your coating collect and analyze data for quality files save information for tracing needs

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Process control basics

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proper process characterization with real and actual process parameters establish process limits real time, in-process continuous process monitoring automatic alerts if exceeding set limits data logging for further improvement
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Diagnosing Thermal Spray WHERE ?

SprayWatch-2i images the particle flow and measures the most significant characteristics of the particles just before they form the coating on the target surface Torch Substrate Spray plume Particles
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Diagnosing Thermal Spray

WHAT ?

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SprayWatch-2i

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SprayWatch 2i

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SprayWatch 2i

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Coating quality control

Process Parameter Particle Velocity Particle temperature Spray angle Spray Position Particle Flux
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Plasma Zr2O3 150 m/s

Plasma Al2O3 180 m/s

HVOF ABC 600 m/s

HVOF XYZ 700 m/s

2250 C

2150 C

1400 C

1400 C

-2,5 degr.

-2,5 degr.

0 degr.

0 degr.

+-0

+-0

+-0

+-0

35

45

25

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Trouble shooting of your process

measured directly detected indirectly

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Diagnosing Thermal Spray

WHOW ?

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SprayWatch Imaging Daignostic System for Thermal Spraying Processes

Based on modern CCD camera and image processing technology Features on-line, inprocess measurement of most important spray and particle parameters
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Diagnosing Thermal Spray

Optical Stripe Filter (pat. pending) enables simultaneous measurement of particle velocity and temperature using a single CCD camera

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SprayWatch-2i Principle of Operation

Particle detection & velocity measurement Exposure time 5-50 s Temperature measurement 1-10 ms

Large measurement volume enables detection of hundreds of particles per second and makes the system sensitive to even the smallest changes in the spray wavelength (nm): 400-1100
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850

700
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SprayWatch Technology Velocity Measurement

A Digital image processing
algorithm developed by Oseir detects the particles automatically

Velocity of individual particles

is measured by time-of-flight method

Range 10 - 1000 m/s, resolution

~ 0.5 m/s

No re-calibration needed
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SprayWatch Technology Temperature Measurement

Optical Stripe Filter (pat. pending) enables simultaneous measurement of particle velocity and temperature using a single CCD camera The spray is imaged through the filter using 1-10 ms exposure time Average temperature of particles is measured by two-color pyrometry at wavelenghts 700 and 850 nm Range: 1000 3500 C , resolution ~ 5 C
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Advantages
The whole spray width measured simultaneously for fast reliable, significant data scanning of spray not needed Easy to install with the help of visual image Easy to operate and fast to set up for use In process measurement with actual production settings
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SprayWatch-2i product family

SprayWatch-2i standard system - SprayWatch-2i/compact system
- 90 and 180 degree options

SprayWatch-2i/portable system - Substrate IR measurement option - HiWatch laser option for cold spray etc. - multiple interface unit
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SprayWatch-2i system
CCD camera based diagnostics system for thermal spraying

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SprayWatch-2i/compact
-intended for continuous process monitoring and mounting on a robot -only abt. 2 lbs weight -same performance as the standard model -manual focus distance setting

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SprayWatch-2i/Portable

For work on the road

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IR substrate surface temperature measurement option

Range 0 500 C, other ranges possible with different sensor

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SprayWatch-2i/laser option

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Diagnosing Cold Spray

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Diagnosing Vacuum system

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Diagnosing inside plasma flame

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Applications
Yield maximization through
Better process understanding and control

Product quality development Process development Real-time process monitoring & alarms Basic research of Spray processes Quality control
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Tested with
Industrial plasma systems from 2,5kW to over 200 kW power and from abt. 5g/min up to 500 g/min powder feed HVOF, HVAF, wire arc, detonation systems, cold pray, vacuum systems etc. large number of various manufacturers spray systems Ceramic and metallic powders
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Summary
Spraywatch-2i is a tool for improving your: customer satisfaction bottom line profitability/competitiveness coating characteristics process control quality control life
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Q&A Web pages: www.oseir.com Contact: info@oseir.com or ismo.linden@oseir.com ITSC2003 booth #511
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