Thermally sprayed coatings used in many applications must meet tight specifications which have been accepted after long and costly development and testing. In a production environment, the use of emerging technologies or new equipment could sometimes lead to important improvements and cost reduction. For example, a higher deposition efficiency process using lower electric power may be available to replace the one that has been used for years to spray a specific coating. However, new technologies have to be tested extensively before being accepted. Generally, this requires a large number of test coupons to be sprayed and characterized due to the many different available combinations of input spray parameters.
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