Process Control in Cold Spraying: Integrating Real-Time In-Situ Monitoring for Manufacturing

Product information

Yaman Sahu, yaman.sahu@tuni.fi, Tampere University; Dr. Jussi Larjo, jussi.larjo@oseir.com, Oseir Oy; Dr. Inigo Floresituarte, inigo.floresituarte@tuni.fi, Tampere University; Dr. Heli Koivuluoto, heli.koivuluoto@tuni.fi, Tampere University; 

https://doi.org/10.53192/ITSC2026550

Cold Spraying (CS) and Cold Spray Additive Manufacturing (CSAM) are rapidly emerging as promising techniques for producing high-quality coatings and structural components. However, current challenges persist in achieving precise geometric accuracy and consistent coating quality over different geometries. This research presents the development and implementation of a fully automatized cold spraying system leveraging real-time, in-situ monitoring and closed-loop control. The system integrates laser profilometry and camera to continuously measure deposit profile and particle in-flight properties such as velocity and size. Real-time data streams are processed and fed into the robot execution program, enabling dynamic adjustment of robot motion and spraying cycles in response to detected coating deviations. This approach ensures uniform deposition thickness and near-net-shape fabrication, even with diverse materials and intricate geometries. In addition, this system represents a significant advancement toward intelligent, sensor-driven process control in cold spraying and additive manufacturing, offering improved quality, reliability, and coating properties.

Reihe

PDF-Download zu https://doi.org/10.53192/ITSC2026550

Erscheinungsdatum

March 2026

Bindung

PDF Download