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Process and quality controlProcess and quality controlwith thermal spray diagnosticswith thermal spray diagnostics

HCAT April 1.-2. 2003 - San Diego, CAby

Mr. Ismo LindénPresidentOseir Ltd.

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WHY ?

WHERE & WHAT ?

WHOW ?

DiagnosDiagnosinging Thermal Spray Thermal Spray

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Higher quality of thermally sprayed partsBetter coatings – competitive edgeBetter reproducibility - yieldLess coating defects - yield

=================================Cost savings & Customer satisfaction

=================================

DiagnosDiagnosinging Thermal Spray Thermal SprayWHY ?WHY ?

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Measurement Is the Basis of QualityMeasurement Is the Basis of Quality

Measure

Control

Quality - through control

- through measurement

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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

For high quality process you need to:For high quality process you need to:

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- proper process characterization with realand actual process parameters

- establish process limits- real time, in-process continuous process

monitoring- automatic alerts if exceeding set limits- data logging for further improvement

Process control basicsProcess control basics

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DiagnosDiagnosinging Thermal Spray Thermal SprayWHERE ?WHERE ?

SprayWatch-2i images the particle flow andmeasures the most significant characteristics ofthe particles just before they form the coating onthe target surface

TorchSubstrate

Spray plume

Particles

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WHAT ?

DiagnosDiagnosinging Thermal Spray Thermal Spray

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SprayWatchSprayWatch-2i-2i

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SprayWatch SprayWatch – 2i– 2i

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SprayWatch SprayWatch – 2i– 2i

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Coating quality controlCoating quality control

+-0+-0+-0+-0SprayPosition

15254535ParticleFlux

0 degr.0 degr.-2,5 degr.-2,5 degr.Sprayangle

1400 C1400 C2150 C2250 CParticletemperature

700 m/s600 m/s180 m/s150 m/sParticleVelocity

HVOFXYZ

HVOFABC

PlasmaAl2O3

PlasmaZr2O3

Process

Parameter

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Trouble shooting of your processTrouble shooting of your process

measureddirectlydetectedindirectly

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WHOW ?

DiagnosDiagnosinging Thermal Spray Thermal Spray

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SprayWatchSprayWatch – Imaging – Imaging DaignosticDaignostic System Systemfor Thermal Spraying Processesfor Thermal Spraying Processes

Based on modernCCD camera andimage processingtechnologyFeatures on-line, in-process measurementof most importantspray and particleparameters

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DiagnosDiagnosinging Thermal Spray Thermal Spray

•Optical Stripe Filter(pat. pending) enablessimultaneousmeasurement of particlevelocity andtemperature using asingle CCD camera

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SprayWatch-2iSprayWatch-2iPrinciple of OperationPrinciple of Operation

Particle detection &velocity measurement

Exposure time 5-50 µs

Temperaturemeasurement

1-10 ms

Large measurement volume enablesdetection of hundreds of particles persecond and makes the system sensitive toeven the smallest changes in the spray

wavelength (nm): 400-1100 850 700

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SprayWatch TechnologySprayWatch TechnologyVelocity MeasurementVelocity Measurement

•A Digital image processingalgorithm developed by Oseirdetects the particles automatically

• Velocity of individual particlesis measured by time-of-flightmethod

•Range 10 - 1000 m/s, resolution~ 0.5 m/s

• No re-calibration needed

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SprayWatch TechnologySprayWatch TechnologyTemperature MeasurementTemperature Measurement

• Optical Stripe Filter (pat. pending) enablessimultaneous measurement of particle velocityand temperature using a single CCD camera

• The spray is imaged through the filter using1-10 ms exposure time

• Average temperature of particles ismeasured by two-color pyrometry atwavelenghts 700 and 850 nm

• Range: 1000 – 3500 °C , resolution ~ 5° C

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AdvantagesAdvantages

The whole spray width measuredsimultaneously for fast reliable, significantdata – scanning of spray not neededEasy to install with the help of visual imageEasy to operate and fast to set up for useIn process measurement with actualproduction settings

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- 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

SprayWatchSprayWatch-2i product family-2i product family

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SprayWatch-2i systemSprayWatch-2i system

CCD camera based diagnostics system forthermal spraying

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SprayWatch-2i/compactSprayWatch-2i/compact

-intended for continuousprocess monitoring andmounting on a robot

-only abt. 2 lbs weight

-same performance as thestandard model

-manual focus distance setting

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SprayWatch-2i/PortableSprayWatch-2i/Portable

For work on the road

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IR substrate surface temperatureIR substrate surface temperaturemeasurement optionmeasurement option

Range 0 – 500 C, other ranges possible with different sensor

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SprayWatch-2i/laser optionSprayWatch-2i/laser option

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Diagnosing Cold SprayDiagnosing Cold Spray

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Diagnosing Vacuum systemDiagnosing Vacuum system

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DiagnosDiagnosinging inside plasma flame inside plasma flame

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ApplicationsApplications

Yield maximization through– Better process understanding and control

Product quality developmentProcess developmentReal-time process monitoring & alarmsBasic research of Spray processesQuality control

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Tested withTested with

Industrial plasma systems from 2,5kW toover 200 kW power and from abt. 5g/minup to 500 g/min powder feedHVOF, HVAF, wire arc, detonationsystems, cold pray, vacuum systems etc.large number of various manufacturersspray systemsCeramic and metallic powders

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SummarySummary

Spraywatch-2i is a tool for improving your:customer satisfactionbottom line – profitability/competitivenesscoating characteristicsprocess controlquality controllife

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Q&AQ&A

Web pages: www.oseir.com

Contact: info@oseir.com

or

ismo.linden@oseir.com

ITSC2003 booth #511