Optimization of robotic trajectories for thermal spray shape deposition

Abstract: "Thermal spray shape deposition is a new process for fabricating net-shape parts by incremental material build-up of cross-sectional layers. This paper presents an approach for spraying thin, flat layers using a robotic spray system. Asymmetries of the spray distribution are first corrected by tilting the spray torch based upon a computer model of the measured spray distribution. The path of the torch is then found using heuristics which are based upon the estimated standard deviation of the corrected distribution. For example, thick arc sprayed coatings (i.e. ̃4mm) have been deposited using this method with the resulting standard deviation from the mean thickness between 20to 30 [mu]m. To demonstrate the shape deposition process, a layered prototype turbine blade shape was built using these optimized trajectories."