Optimizing the Plasma Spray Process Parameters of Yttria Stabilized Coatings on Aluminum Alloy Using Response Surface Methodology
B.Kumaragurubaran1, T.Parthipa Saravana Kumar2, T.Senthil Kumar3, M. Chandrasekar4
1B.Kumaragurubaran, Department of Mechanical Engineering, Bharathidasan Institute of Technology, Anna University, Tiruchirappalli, (Tamil Nadu), India.
2T.Parthipa Saravana Kumar, Department of Mechanical Engineering, Bharathidasan Institute of Technology, Anna University, Tiruchirappalli, (Tamil Nadu), India.
3T.Senthil Kumar, Department of Mechanical Engineering, Bharathidasan Institute of Technology, Anna University, Tiruchirappalli, (Tamil Nadu), India.
4M. Chandrasekar, Department of Mechanical Engineering, Bharathidasan Institute of Technology, Anna University, Tiruchirappalli, (Tamil Nadu), India.
Manuscript received on May 29, 2013. | Revised Manuscript received on June 11, 2013. | Manuscript published on June 30, 2013. | PP: 377-384 | Volume-2, Issue-5, June 2013. | Retrieval Number: E1863062513/2013©BEIESP
Open Access | Ethics and Policies | Cite
© The Authors. Blue Eyes Intelligence Engineering and Sciences Publication (BEIESP). This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
Abstract: Atmospheric plasma spraying is used extensively to make Thermal Barrier Coatings of 7-8% yttria-stabilized zirconia powders. The main problem faced in the manufacture of yttriastabilized zirconia coatings by the atmospheric plasma spraying process is the selection of the optimum combination of input variables for achieving the required qualities of coating. This problem can be solved by the development of empirical relationships between the process parameters (current, powder feed rate, stand-off distance, no of passes) and the coating quality characteristics (coating thickness, coating hardness and porosity) through effective and strategic planning and the execution of experiments by response surface methodology. This article highlights the use of response surface methodology by designing four factor five level central composite rotatable design matrixe with full replication for planning, conduction, execution, and development of empirical relationships. Further, response surface methodology was used for the selection of optimum process parameters to achieve desired quality of yttria-stabilized zirconia coating deposits on aluminum alloy.
Keywords: Plasma spray, statistical experiments, response surface methodology, yttria stabilized zirconia, coating thickness, porosity, coating hardness.