Application of Taguchi Method to the Optimization of Detonation Spraying Process

The present study deals with an application of the Taguchi method to the optimization of a detonation spray process for alumina coatings. Coating experiments were conducted using the TaguchUfractional factorial (L₈) design parametric study to optimize spray process parameters. The Taguchi design evaluated the effects of four detonation spray process parameters: acetylene to oxygen ratio, carrier gas flow rate, frequency of detonations and spray distance. The coating qualities evaluated were surface roughness, porosity, microhardness, and abrasion mass loss. The influence of process parameters on the as-sprayed coating qualities is discussed. The results of the study indicate that the higher fuel ratio and lower spray distance will result in higher hardness, lower porosity and lower abrasion mass loss. The Taguchi analysis employed in the present investigation led to optimized process parameters for the most abrasive wear resistant alumina coatings.