Cyber Materials LLC

Randy Lee Bewley

James R Fincke

Michael Alan Gevelber

William David Swank

Delon C Haggard

Donald Edward Wroblewski

An improved automatic feedback control scheme enhances plasma spraying of powdered material through reduction of process variability and providing better ability to engineer coating structure. The present inventors discovered that controlling centroid position of the spatial distribution along with other output parameters, such as particle temperature, particle velocity, and molten mass flux rate, vastly increases control over the sprayed coating structure, including vertical and horizontal cracks, voids, and porosity. It also allows improved control over graded layers or compositionally varying layers of material, reduces variations, including variation in coating thickness, and allows increasing deposition rate. Various measurement and system control schemes are provided.

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Blackfoot, ID, United States of America

Randy Lee Bewley