NDLI: Optimization of Atmospheric Plasma Spray Process Parameters using a Design of Experiment for Alloy 625 coatings

Content Provider	Springer Nature Link
Author	Azarmi, F. Coyle, T.W. Mostaghimi, J.
Copyright Year	2008
Abstract	Alloy 625 is a Ni-based superalloy which is often a good solution to surface engineering problems involving high temperature corrosion, wear, and thermal degradation. Coatings of alloy 625 can be efficiently deposited by thermal spray methods such as Air Plasma Spraying. As in all thermal spray processes, the final properties of the coatings are determined by the spraying parameters. In the present study, a D-optimal experimental design was used to characterize the effects of the APS process parameters on in-flight particle temperature and velocity, and on the oxide content and porosity in the coatings. These results were used to create an empirical model to predict the optimum deposition conditions. A second set of coatings was then deposited to test the model predictions. The optimum spraying conditions produced a coating with less than 4% oxide and less than 2.5% porosity. The process parameters which exhibited the most important effects directly on the oxide content in the coating were particle size, spray distance, and Ar flow rate. The parameters with the largest effects directly on porosity were spray distance, particle size, and current. The particle size, current, and Ar flow rate have an influence on particle velocity and temperature but spray distance did not have a significant effect on either of those characteristics. Thus, knowledge of the in-flight particle characteristics alone was not sufficient to control the final microstructure. The oxidation index and the melting index incorporate all the parameters that were found to be significant in the statistical analyses and correlate well with the measured oxide content and porosity in the coatings.
Starting Page	144
Ending Page	155
Page Count	12
File Format	PDF
ISSN	10599630
Journal	Journal of Thermal Spray Technology
Volume Number	17
Issue Number	1
e-ISSN	15441016
Language	English
Publisher	Springer US
Publisher Date	2008-01-04
Publisher Place	Boston
Access Restriction	One Nation One Subscription (ONOS)
Subject Keyword	coating optimization using DOE influence of spray parameters porosity of coatings APS coatings oxidation in APS coatings Analytical Chemistry Operating Procedures, Materials Treatment Characterization and Evaluation of Materials Materials Science 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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