Aeroacoustic Free-Field Microphony for Process Stability and Nozzle Clogging Detection in Atmospheric Plasma Spray

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Manuela Ockel, Christiane Dötsch, christiane.doetsch@faps.fau.de, Thomas Hanft, thomas.hanf@faps.fau.de, Prof. Dr.-Ing. Jörg Franke, Joerg.franke@faps.fau.de
FAU Erlangen

https://doi.org/10.53192/ITSC2026504 

The monitoring of atmospheric plasma spray processes (APS) is often limited to the plasma flame via particle diagnostic systems and emission spectroscopy and supplemented by machine parameters. However, reflections and changing light conditions potentially increase the complexity of controlling the APS process. Changes in the plasma flame resulting from nozzle clogging are challenging to detect optically during coating. Theoretically, alterations in flow rates of fine powders (d < 12 µm) can be identified by the flow watch, which is employed for the monitoring of powder conveyors. Nevertheless, it should be noted that all disturbances occurring during conveying and powder injection remain unmonitored and are critical for low conveying rates. The development of a process monitoring system based on acoustic pressure and one-third octave analysis was enabled by the implementation of aeroacoustics, which was detected by free-field microphones positioned outside the coating chamber to prevent issues of microphone contamination and wear. The study evaluates the feasibility of detecting not only nozzle clogging, but also variations in plasma flame conditions.

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Erscheinungsdatum

March 2026

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