Application of Taguchi Method to the Optimization of Detonation Spraying Process

Saravanan, P.; Selvarajan, V.; Rao, D. Srinivasa; Joshi, S.V.; Sundararajan, G.

doi:10.1080/10426910008912978

Cited by 10 publications

(3 citation statements)

References 2 publications

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“…The same authors applied an L 8 (2 4-1 ) fractional factorial Taguchi design to evaluate the effects of four detonation spray process parameters (acetylene-to-oxygen ratio, powder carrier gas flow rate, detonation frequency, and stand-off distance) on surface roughness, porosity, microhardness, and abrasion mass loss of alumina coatings. High fuel-to-oxygen ratio and low stand-off distance promote coatings with higher hardness, lower porosity, and lower abrasion mass loss (Ref [17][18][19]. Kucuk et al (Ref 20) examined the mechanical properties of Y-stabilized zirconia thermal barrier coatings (TBCs), plasma-sprayed onto a NiCrAlY bond coat using a 9-run L 8 (2 4-1 ) fractional Taguchi design with one center point as well as a 17-run L 16 (2 4 ) full Taguchi design with one center point, varying the YSZ top coat thickness, t TC (300 or 500 lm), NiCrAlY bond coat thickness, bond coat thickness, t BC (100 or 250 lm), substrate temperature, T S (273 or 393 K) and stand-off distance, X (80 or 100 mm).…”

Section: Taguchi Designsmentioning

confidence: 99%

Better Quality Control: Stochastic Approaches to Optimize Properties and Performance of Plasma-Sprayed Coatings

Heimann¹

2009

J Therm Spray Tech

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Statistical design of experiment (SDE) methodology applied to design and performance testing of plasma-sprayed coatings follows an evolutionary path, usually starting with classic multiparameter screening designs (Plackett-Burman), and progressing through factorial (Taguchi) to limited response surface designs (Box-Behnken). Modern designs of higher dimensionality, such as central composite and D-optimal designs, will provide results with higher predictive power. Complex theoretical models relying on evolutionary algorithms, and application of artificial neuronal networks (ANNs) and fuzzy logic control (FLC) allow estimating the behavior of the complex plasma spray environment through validation either by key experiments or first-principle calculations. In this review, paper general principles of SDE will be discussed and examples be given that underscore the different powers of prediction of individual statistical designs. Basic rules of ANN and FLC will be briefly touched on, and their potential for increased reliability of coating performance through stringent quality control measures assessed. Salient features will be reviewed of studies performed to optimize thermal coating properties and processes reported in the pertinent literature between 2000 and the present.

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Section: Taguchi Designsmentioning

confidence: 99%

Better Quality Control: Stochastic Approaches to Optimize Properties and Performance of Plasma-Sprayed Coatings

Heimann¹

2009

J Therm Spray Tech

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“…Alumina-zirconia ceramic composite has the least sliding wear among the D-gun sprayed alumina-based ceramic composite coatings [2]. In D-gun spraying, higher fuel ratio and lower spray distance result in lower porosity, higher hardness and lower wear loss [3]. The investigation on the variation in the microstructure and phase changes of the sprayed deposits reveals that chemical transformation forming minor phases lead to the strengthening of the deposits and consequently higher hardness [4].…”

Section: Original Articlementioning

confidence: 99%

Investigation on the Influence of Substrate Materials on the Tribological Behavior of Detonation Gun Sprayed Alumina Coating

Haridasan¹,

Tjprc²

2018

IJMPERD

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Detonation Gun (D-Gun) Spray Coating is a widely used surface strengthening process applicable for many machine elements and engineering components. D-Gun process gives the unique capability to produce hard surface layers with residual compressive stress, superior adhesive strength and the least porosity in comparison with other thermal spray processes. In addition, flexibility to manufacture the components initially using relatively softer and cheaper materials followed by modification of the functional surfaces using detonation gun spraying of harder materials is a welcome alternative. Experiments were conducted to study the influence of select substrate materials on the behavior of the detonation gun sprayed alumina coatings using optimized process parameters. The experimental investigations relied on the measurement of microhardness, surface roughness, friction and wear behavior as well as by Scanning Electron Microscope (SEM) image analysis of the sprayed alumina coatings on different substrate materials-Stainless Steel SS304, SS316 and Aluminum alloy AA1050. Experimental results suggest that the tribological response of the alumina coated on aluminum alloy in comparison with stainless steels produced durable surface coatings that are superior in resisting environmental degradation.

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“…The amount of Al in the coating, however, should not be in excess because this may deteriorate the dynamic and fabricating properties of the coating. Too much Cr in the coating, on the other hand, can pollute the environment, endanger the health of the operator, and cause other problems[5][6][7]. Cr 3 C 2 RE composite coating has better microstructure and finer crystals than Fe-Al/Cr 3 C 2 composite coating.…”

mentioning

confidence: 99%

Microstructure and Properties of Fe–Al/Cr<sub>3</sub>C<sub>2</sub>RE Composite Coating Produced by HVFS

Liu

Dong

Xu³

2011

AMR

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Fe–Al/Cr3C2composite coatings produced from high-velocity flame spraying (HVFS) are Fe–Al intermetallic composite coatings with remarkable room-temperature and high-temperature properties. However, Fe–Al/Cr3C2composite coatings have a Cr3C2content of 50%. This causes the coatings to become porous and limits its room-temperature and high-temperature properties. In order to improve microstructure and properties of Fe–Al/Cr3C2composite coatings, Fe–Al/Cr3C2RE, including Fe–Al/Cr3C2and CeO2, is sprayed by HVFS technology onto AISI 1020 steel. The properties including bonding strength and high-temperature corrosion-resistance of Fe–Al/Cr3C2RE composite coating are tested at 25°C and 650 °C. For comparison, two other materials, substrate AISI 1020 steel and Fe–Al/Cr3C2composite coating, are tested under the same experimental conditions. The microstructures of the coatings are analyzed by scanning electronic microscopy (SEM), the cross-section morphology of Fe–Al/Cr3C2RE composite coating is analyzed by energy-dispersive spectroscopy (EDS), and the existing states of oxides are analyzed by transmission electron microscopy (TEM). The phases of the composite coating after corrosion are analyzed by X-ray diffraction (XRD). The results demonstrate that the properties of Fe–Al/Cr3C2RE composite coatings is better than that of either AISI 1020 steel or the Fe–Al/Cr3C2composite coating. CeO2is a surface-active agent, and it significantly improves the microstructure and properties of Fe–Al/Cr3C2RE composite coating. CeO2improves the bonding strength of Fe–Al/Cr3C2RE composite coating by reducing the surface tension of droplet and enhancing its fluidity as well as wetting capacity on the surface of the substrate, decreasing the internal stress of coating.Adding CeO2to the coating produces Al2O3and Cr2O3oxide films, which protect the substrate AISI 1020 steel from corrosion more efficiently.

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Application of Taguchi Method to the Optimization of Detonation Spraying Process

Cited by 10 publications

References 2 publications

Better Quality Control: Stochastic Approaches to Optimize Properties and Performance of Plasma-Sprayed Coatings

Better Quality Control: Stochastic Approaches to Optimize Properties and Performance of Plasma-Sprayed Coatings

Investigation on the Influence of Substrate Materials on the Tribological Behavior of Detonation Gun Sprayed Alumina Coating

Microstructure and Properties of Fe–Al/Cr<sub>3</sub>C<sub>2</sub>RE Composite Coating Produced by HVFS

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