SBIR Phase II: An Imaging Sensor for Measuring and Controlling the Particle Conditions in Thermal Sprays

这个小型企业创新研究(SBIR)第二阶段项目将开发一种短曝光成像传感器，用于测量和控制热喷雾中的粒子温度和速度。热喷涂是金属加工业中一个快速发展的元素，需要过程控制。目前，由于缺乏传感器来提供实时测量，因此没有直接的颗粒状态控制。这种成像传感器技术将连续观察整个粒子流，利用传感器光谱范围内的整个发射，并使用快速图像处理算法来获得在线测量。第二阶段将开发传感器响应模型、硬件和软件设计，并将构建传感器原型并进行校准测试。这些传感器将被集成到过程控制系统中，并在工业环境中运行。热喷涂技术正在改变和改进汽车、航空航天、能源和重型设备行业制造高质量金属部件的方式。传感器和热喷涂控制将通过在表面涂覆金属和陶瓷，提供新的成本效益和一致性，以应对材料加工中的挑战，即热、磨损和腐蚀。

This Small Business Innovation Research (SBIR) Phase II project will develop a short-exposure imaging sensor for measuring and controlling particle temperature and velocity of thermal sprays. Thermal spray is a rapidly growing element of the metals processing industry, which needs process control. Currently, there are no direct particle condition controls, for lack of a sensor to provide real-time measurements. This imaging sensor technology will continuously view the entire particle stream, utilize the entire emission across the spectral range of the sensor, and employ fast image processing algorithms to obtain on-line measurements. Phase II will develop a sensor response model, hardware and software design, and prototype sensors will be constructed and calibration tested. These sensors will be incorporated in process control systems and operated in an industrial environment.Thermal spray technology is changing and improving the way high quality metal parts are manufactured for the automotive, aerospace, energy, and heavy equipment industries. Sensor and thermal spray controls will provide new levels of cost efficiency and consistency to challenges in material processing, namely thermal, wear and corrosion, by coating the surface with metals and ceramics.