Study of plasma- and detonation gun-sprayed alumina coatings using taguchi experimental design |
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Authors: | P Saravanan V Selvarajan M P Srivastava D S Rao S V Joshi G Sundararajan |
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Affiliation: | (1) Department of Physics, Bharathiar University, 641 046 Coimbatore, India;(2) Defence Metallurgical Research Laboratory, 500 058 Hyderabad, India;(3) International Advanced Research Centre for Powder Metallurgy & New Materials, 500 005 Hyderabad, India |
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Abstract: | Atmospheric plasma spraying (APS) is a most versatile thermal spray method for depositing alumina (Al2O3) coatings, and detonation gun (D-gun) spraying is an alternative thermal spray technology for depositing such coatings with
extremely good wear characteristics. The present study is aimed at comparing the characteristics of Al2O3 coatings deposited using the above techniques by using Taguchi experimental design.
Alumina coating experiments were conducted using a Taguchi fractional-factorial (L8) design parametric study to optimize the spray process parameters for both APS and D-gun. The Taguchi design evaluated the
effect of four APS and D-gun spray variables on the measured coating attributes. The coating qualities evaluated were surface
roughness, porosity, microhardness, abrasion, and sliding wear. The results show that the coating quality is directly related
to the corresponding coating microstructure, which is significantly influenced by the spray parameters employed. Though it
is evident that the D-gun-sprayed coatings consistently exhibit dense and uniform microstructure, higher hardness, and superior
tribological performance, the attainment of suitable plasma-sprayed coatings can be improved by employing the Taguchi analysis. |
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Keywords: | abrasion alumina coating design of experiments d-gun coatings DOE optimization plasma spray coatings sliding wear Taguchi analysis |
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