Abstract: A thermal spray system may include a thermal spray torch configured to produce an emission of material, at least one camera configured to capture an image of the emission of material emitted by the thermal spray torch, a diagnostic device communicatively coupled to the at least one camera, and a controller communicatively coupled to the diagnostic device. The camera may be configured to transmit an image of the emission of material to a diagnostic device that may be configured to determine a characteristic of the emission of material based on the image. The diagnostic device may transmit the characteristic to a controller that may control a position of the thermal spray torch based on the characteristic.

Abstract: A system for checking calibration of a multi-axis machine includes a robotic arm and a mount configured to receive a removable machine tool and a controller electronically connected to the multi-axis machine. The removable machine tool includes a removable spray nozzle and a laser housing that is coupled to the machine tool. The laser housing includes a laser affixed inside the housing for emitting a laser beam and a calibration workpiece coupled to a mounting table. The calibration workpiece comprises a plurality of laser sensors disposed along an outer surface of the calibration workpiece. The controller is programmed to point the laser beam at each laser sensor. The laser sensors generate signals that are communicated back to the controller if the laser beam is detected by the laser sensor.

Abstract: A thermal spray system may include a thermal spray torch configured to produce an emission of material, at least one camera configured to capture an image of the emission of material emitted by the thermal spray torch, a diagnostic device communicatively coupled to the at least one camera, and a controller communicatively coupled to the diagnostic device. The camera may be configured to transmit an image of the emission of material to a diagnostic device that may be configured to determine a characteristic of the emission of material based on the image. The diagnostic device may transmit the characteristic to a controller that may control a position of the thermal spray torch based on the characteristic.

Abstract: A method for manufacturing components is provided. The method includes coupling a drive assembly to a positioning assembly, coupling a plurality of components to be manufactured to a plurality of fixtures, securing the plurality of fixtures to the drive assembly wherein each fixture is configured to receive a component to be manufactured, and repositioning the plurality of components simultaneously using the positioning assembly to facilitate manufacturing of the plurality of components, wherein the components are configured to be oscillated in a first plane of rotation via the drive assembly and rotated through a second plane of rotation via the plurality of fixtures.

Abstract: A coated article comprises a substrate; and a multilayer thermal barrier coating disposed on the substrate, the multilayer thermal barrier coating comprising at least a first layer comprising a first ceramic composition having a thermal conductivity less than 1 W/m° K; a second layer having an erosion resistance greater than or equal to dense vertically cracked 8% yttrium stabilized zirconia, wherein percent is based on a total weight of yttrium and zirconia, and a third layer comprising the first ceramic composition or the second composition, wherein the first, second, and third layers are arranged such that the first ceramic composition and the second composition are in alternating layers.