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For high process reproducibility and optimized coating quality in thermal spray applications on complex geometries, atmospheric plasma spraying and high-velocity oxygen fuel torches are guided by advanced robot systems. The trajectory of the torch, the spray angle, and the relative speed between torch and component are crucial factors which affect the coating microstructure, properties, and, especially, the residual stress distribution. Thus, the requirement of high-performance thermally sprayed coatings with narrow dimensional tolerances leads to challenges in the field of robot-assisted handling, and software tools for efficient trajectory generation and robot programming are demanded. By appropriate data exchange, the automatically generated torch trajectory and speed profile can be integrated in finite element method models to analyze their influence on the heat and mass transfer during deposition. Coating experiments assisted by online diagnostics were performed to validate the developed software tools.

In der Automobilindustrie ist in den vergangenen Jahren die Nachfrage nach Leichtbauwerkstoffen und Leichtbaukonstruktionen signifikant gestiegen. Hauptmotivationsgründe dafür sind vor allem die Reduzierung des Kraftstoffverbrauchs und der Schadstoffemissionen, aber auch die Verringerung der Herstellungskosten durch neue, vollautomatisierte, schnellere und insbesondere kosten-

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