Industrial type fully digital diagnostic system was developed in the frame of BRITE Project BE 97-5040 for particles velocity and temperature monitoring in thermal
spraying. The system is based on the new CCD structure image sensor that provides higher sensitivity in the near infrared spectral region and higher saturation signal level than the
conventional devises. The diagnostic system and special software for image treatment have been tested under actual industrial conditions of plasma spraying (in the range 20-50 kW) of Al203 and Zr02+8%Y203 powders. Diagnostic system demonstrates high performance
in plasma spraying monitoring: 20 μm particle size detection limit; 1500 K minimum detectable brightness temperature; 700 mls maximum particle velocity.