Thermal spray diagnostics

A method comprising:

• receiving, by a computing device, from at least one acoustic sensor, at least one time-dependent acoustic data signal indicative of an acoustic signal generated by a thermal spray system performing a process possessing a plurality of process attributes;
• transforming, by the computing device, the at least one time-dependent acoustic data signal to a frequency-domain spectrum, wherein each process attribute of the plurality of process attributes is associated with at least one respective frequency band;
• and
• determining, by the computing device, a process attribute of the plurality of process attributes by identifying at least one characteristic of the frequency-domain spectrum.

A computer readable storage medium comprising instructions that, when executed, cause at least one processor to:

• receive, from at least one acoustic sensor, at least one time-dependent acoustic data signal indicative of an acoustic signal generated by a thermal spray system performing a process possessing a plurality of process attributes;
• transform the at least one time-dependent acoustic data signal to a frequency-domain spectrum, wherein each process attribute of the plurality of process attributes is associated with at least one respective frequency band;
• and
• determine a process attribute of the plurality of process attributes by identifying at least one characteristic of the frequency-domain spectrum.