Optimization of the Quality Characteristics of Laser-Assisted Cold-Sprayed (LACS) Aluminum Coatings with Taguchi Design of Experiments (DOE)

This study employs Taguchi design of experiments to identify optimal process parameters (deposition temperature, transverse speed, powder feed rate, and operating pressure) associated with quality characteristics (porosity and hardness) of laser-assisted cold-sprayed (LACS) pure aluminum coatings. Optimal quality characteristics of the coatings were obtained by setting deposition temperature at 450°C, transverse speed at 5 mm/s, operating pressure at 30 bar, and powder feed rate at 25 rev/min. This study helps in improving the yield and stability of pure aluminum coatings produced via LACS process while it also reduces its variability which results in high rejection, rework, and warranty costs.