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Video-Based Prediction of In-Flight Particle Characteristics in Atmospheric Plasma Spraying

Atmospheric plasma spraying (APS) is a widely used coating process in which in-flight particle temperature and velocity strongly influence coating quality. However, these particle characteristics are difficult to monitor continuously during operation, motivating the development of non-invasive data-driven diagnostic methods. In this work, we investigate the predictive potential of high-speed video observations of the plasma plume for estimating in-flight particle characteristics in APS. We introduce three different video-derived feature representations and evaluate them using Tabular Prior-Data Fitted Networks (TabPFN), convolutional neural networks (CNN), and classical regression baselines including Random Forest, Gradient Boosting, Support Vector Regression, and XGBoost. Experiments are conducted using grouped leave-one-out cross-validation on 126 labeled pre- and post-spray video recordings from 63 APS spray runs. Across the engineered feature experiments, TabPFN achieves the most consistent performance for temperature prediction, reaching R2 = 0.86 using the combined feature representation. CNN models particularly perform stronger for velocity prediction, achieving R2 of 0.81. In addition, we evaluate models operating directly on raw video frames using pretrained CNNs and find that the highest performance is achieved by a pretrained CNN with a regression head with R2 of 0.90 and 0.82 for temperature and velocity, respectively. The results demonstrate that video-derived plume information provides a promising and scalable foundation for non-invasive APS diagnostics and real-time process monitoring.

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