Fabrication of Ultra-Stable and Customized High-Temperature Speckle Patterns Using Air Plasma Spraying and Flexible Speckle Templates

Reliable and accurate full-field deformation measurements at elevated temperatures using digital image correlation (DIC) require stable and high-contrast high-temperature speckle patterns to be prepared on the sample surface. However, conventional high-temperature speckle patterns fabricated by the existing methods possess several limitations, e.g., easily fail to preserve original pattern features due to the harsh environment and heavily dependent on the operator’s experience. In this study, we propose a reliable and reproducible high-temperature speckle fabrication method based on air plasma spraying (APS) and flexible speckle templates. This method involves covering the sample surface with pre-designed speckle templates and then spraying the melted speckle powders onto the specimen surface using an air plasma spray technique to obtain customized speckle patterns. The validity of the proposed method was verified by the speckle fabrication on both planar and curved samples and heating tests with these samples. Experimental results demonstrate that the speckle patterns made by the proposed method adhere well to the sample surface, remain stable during the heating process, and exhibit excellent agreement with the reference values in terms of the thermal expansion coefficients. The proposed method provides a reliable and efficient way to create customized and stable speckle patterns for accurate high-temperature DIC measurements.