Purpose: The purpose of this paper is to propose cold spraying and laser cladding processes as alternatives to cadmium and chromium electroplating, respectively. There are many substances or chemicals within the coating technology that can be identified as substances of very high concern because of their carcinogenic or mutagenic nature. Cadmium and chromium undoubtedly belong to these items and are the basic constituents of electrolytic coating processes. Finding an alternative and adapting to the existing restrictions of the usage of such hazardous products stands for many to be or not to be in the market. Design/methodology/approach: The research work was focused on down selecting the appropriate materials, producing the coating samples, testing their properties and optimizing process parameters by statistical method. On the one hand, the high-pressure cold spray system and spraying of the titanium coating on the landing gear component, and on the other hand, the high-energy laser cladding facility and the wear resistant cobalt-based coating deposited onto the shock absorber piston. Substrates of these two applications were made of the same material, 4330 – high-strength low-carbon steel. Findings: Meeting the requirements of Registration, Evaluation, Authorization and Restriction of Chemicals implies undertaking research and implementation work to identify alternative processes. The work provides the technical characteristics of new coatings justifying application readiness of the researched processes. Originality/value: Taguchi’s design of experiment method was combined with the measurements and analysis of specified coating properties for the optimization of the cold spray process parameters. There is also laser cladding process development presented as a fast rate technology generating coatings with the unique properties.

Imaging scatterometry is a method for determining the reflection distribution based on bidirectional reflectance distribution function (BRDF) measurements. However, it has a well-known limitation that results obtained by imaging scatterometry for small illumination angles are practically useless. Therefore, we propose an approach for reconstruction of the reflection distribution based on a series of measurements at different illumination angles and extrapolation of the missing results to overcome this limitation. The developed algorithm was validated using bidirectional transmittance distribution function (BTDF) measurements. The BRDF measurements were carried out for materials that are commonly used in laser material processing, i.e. substrates and functional coatings. The obtained data were subsequently used to determine the total reflection intensity from all considered materials, which were characterized by reconstructed distributions.