Taguchi design method of optimization facilitates standard experimental research, lowers cost, conserves energy and time, minimizes waste and ensures optimal outcomes. In this work, Taguchi L9 3 4 orthogonal array, signal-to-noise (S/N) ratio and analysis of variance (ANOVA) statistical procedures were applied to evaluate the influence of sintering parameters/levels on the relative densification and microhardness of Ti-6Al-4V/h -BN binary composite sintered. The S/N ratios revealed that heating rate with delta value of 0.24, followed by temperature with delta value of 0.22 impart the most significant influence on the optimal quality characteristics. One-way ANOVA statistical analyses showed that heating rate imparts the greatest influence on relative densification with 36.25% contribution, followed by temperature with 31.33% contribution, whereas temperature gave the highest contribution of 34.12%, followed by heating rate with 23.31% contribution for microhardness. The optimal parameters/levels for most desirable characteristics were obtained at 1000 °C, 30 MPa, 100 °C min −1 and 10 min. The spark plasma sintered Ti6Al4V-3h-BN composite with the optimized parameters/levels attained nearly full theoretical densification of 99.54% and the sintered composite gave a microhardness value of 716.43 HV which is more than 200% that of the monolithic alloy. The confirmation test revealed that the improvement in relative densification and microhardness at the optimum parameters/levels are 1.55% and 19.2% of the arithmetic means of the initial relative densification and microhardness measurements respectively.
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