Acoustic real-time fault monitor for thermal spray coating
This system uses microphones or acoustic sensors placed around a thermal spray machine — a device that blasts molten material onto surfaces to create coatings — to listen to the sounds the machine makes while it operates. The system converts those sounds into frequency patterns and matches specific frequencies to specific parts of the machine and specific operating conditions like gas flow rates, temperatures, or material feed behavior. If something goes wrong — a clogged powder feed, a gas leak, worn components — the system detects the acoustic signature of that problem and fires an alert, all in real time without interrupting production. It essentially turns sound into a continuous quality and fault-detection monitor for a process that is otherwise difficult to inspect mid-operation.
What you could build
A retrofit or OEM-integrated acoustic monitoring module for industrial thermal spray equipment — sold to aerospace MRO shops, turbine blade coating facilities, and automotive surface treatment lines — that provides real-time fault alerts and process logging without requiring process interruption.
Who in Virginia should care
Virginia's defense and aerospace manufacturing base — including facilities supporting the Navy and Air Force depots — routinely uses thermal spray for component repair and coating, making this relevant to MRO contractors and defense primes operating in the state.
Readiness: Prototype likely
Concept — described but not yet demonstrated. Lab validated — supported by experimental results in the patent. Prototype likely — the text describes a built, working embodiment.
Readiness is inferred from the patent text, not from a lab visit.
The record
- Inventors
- Michael Cybulsky, Raymond J. Sinatra, Matthew R. Gold, Taylor K. Blair, Gary Pickrell, Romesh Batra
- Granted
- July 28, 2020
- Status
- Granted patent
- Patent number
- 10724999
Ready to talk?
Virginia Tech Intellectual Properties handles licensing for this technology.
Prosim summaries are generated from public patent text and are not legal advice.