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



Stephen D. Ridder


This report covers the second workshop on TS coatings sponsored by the NIST Metallurgy Division. The first of these workshops, held in November, 1998, is 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 US industry. Attendance from outside NIST was approximately 35, of whom 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.In the December 2000 issue of the Journal of Thermal Spray Technology, R.C. Tucker, Jr. gave Comments on the Status and Future of Thermal Spray Coatings. These comments discussed many of the issues covered in this workshop and stressed the need for higher quality in thermal spray coatings. Tucker s comments are recommended background reading for this report.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 are 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, especially 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.
NIST Interagency/Internal Report (NISTIR) - 6776
Report Number


coating reliability, imaging pyrometry, process control, process diagnostics, sensors, thermal spray coatings


Ridder, S. (2001), Thermal Spray Process Reliability: Sensors and Diagnostics; Summary of a Workshop held at National Institute of Standards and Technology, NIST Interagency/Internal Report (NISTIR), National Institute of Standards and Technology, Gaithersburg, MD (Accessed July 24, 2024)


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Created January 1, 2001, Updated October 16, 2008