NDLI: Optimization of Plasma Spray Process Using Statistical Methods

Content Provider	Springer Nature Link
Author	Gao, F. Huang, X. Liu, R. Yang, Q.
Copyright Year	2011
Abstract	The microstructure features of coatings produced by a plasma spray process are affected significantly by the process parameters such as powder size, spray gun nozzle size, total plasma gas flow, ratio of H$_{2}$ + N$_{2}$ over total gas flow, and so on. This article presents a study of the effects of these parameters on the microstructure (porosity, formation of crack, unmelted particle and oxide phase) of NiCrAlY coatings deposited by the Mettech Axial III™ System. A Taguchi array is used to design the spraying process parameters. The results of the microstructure evaluation are used to generate regression equations for the prediction of coating microstructure based on process parameters. The results predicted from the regression equations are in good agreement with the experimental results according to a confidence level of 0.95. Among the parameters examined, the powder size and the ratio of H$_{2}$ + N$_{2}$ over total gas flow rate are the most significant parameters affecting the occurrence of crack, porosity, unmelted particle and oxide. Within the range of the designed process parameters, lower powder size and higher ratio of H$_{2}$ + N$_{2}$ over total gas flow rate lead to less cracks, pores, unmelted particles but more oxides. Nozzle size has marginal influence on oxides which increase with nozzle size. Gas flow rate has no direct influence on any coating feature evaluated with the range of variation.
Starting Page	176
Ending Page	186
Page Count	11
File Format	PDF
ISSN	10599630
Journal	Journal of Thermal Spray Technology
Volume Number	21
Issue Number	1
e-ISSN	15441016
Language	English
Publisher	Springer US
Publisher Date	2011-11-22
Publisher Place	Boston
Access Restriction	One Nation One Subscription (ONOS)
Subject Keyword	axial injection crack NiCrAlY coating oxide plasma spray porosity process optimization regression equation Taguchi method unmelted particle Analytical Chemistry Materials Science Operating Procedures, Materials Treatment Characterization and Evaluation of Materials Tribology, Corrosion and Coatings Surfaces and Interfaces, Thin Films
Content Type	Text
Resource Type	Article
Subject	Surfaces, Coatings and Films Materials Chemistry Condensed Matter Physics

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