I n s i t u measurement of coating thickness during thermal spraying using an optical displacement meter

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Abstract
An optical diplacement meter was developed to measure and control the thickness of coatings deposited by thermal spraying. The displacement of the surface of a workpiece was monitored continuously during the spraying process by detecting the position of a bright spot made on the surface by laser illumination using a linear image sensor. A cylindrical lens was used to reduce the error due to speckle and a differential method was employed to discriminate the coating thickness from the displacement due to thermal deformation. By stopping deposition when the meter output reached a predetermined value, the thickness of plasma sprayed alumina coating could be controlled with a standard deviation of 24 μm.

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