AE Monitoring and Analysis of HVOF Thermal Spraying Process

N. H. Faisal, R. Ahmed, R. L. Reuben, B. Allcock

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9 Citations (Scopus)
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This work presents an in situ monitoring of HVOF thermal spraying process through an acoustic emission (AE) technique in an industrial coating chamber. Single layer thermal spraying on substrate was carried out through slits. Continuous multilayer thermal spraying onto the sample without slit was also conducted. The AE was measured using a broadband piezoelectric AE sensor positioned on the back of the substrate. A mathematical model has been developed to determine the total kinetic energy of particles impacting the substrate through slits. Results of this work demonstrate that AE associated with particle impacts can be used for in situ monitoring of coating process. Results also show that the amplitude and AE energy is related to the spray gun transverse speed and the oxy-fuel pressure. The measured AE energy was found to vary with the number of particles impacting the substrate, determined using the mathematical model. © 2011 ASM International.

Original languageEnglish
Pages (from-to)1071-1084
Number of pages14
JournalJournal of Thermal Spray Technology
Issue number5
Publication statusPublished - Sept 2011


  • acoustic emission
  • HVOF
  • monitoring
  • multilayer spraying
  • non-destructive testing
  • particle impact
  • thermal spray


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