Online cold spray process monitoring by real time diagnostics

Cold spray processing has demonstrated its potential as an additive manufacturing method, capable of producing thick coatings or bulk structures from various feedstock materials, such as aluminum and titanium -based alloys. Transitioning from traditional coating manufacturing to additive manufacturing increases production time and introduces new challenges for process control. This study focuses on a novel online cold spray process monitoring system that uses in-situ diagnostics during cold spraying and cold spray additive manufacturing. It combines the in-flight behavior of particles with the expected properties of the resulting coatings. When the diagnostic camera noticed variations or drops in the particle velocities or distribution, lower coating quality was detected. These findings traced the way for in-situ analysis of coating quality, allowing for the identification of issues such as nozzle clogging and uneven powder flow during the process. This proactive approach helps to minimize defects in the coatings. Comparing particle in-flight data with coating structures confirmed the effectiveness of in-situ monitoring as a quality control measure during cold spray processing.