Surface roughness optimization of cold-sprayed coatings using Taguchi method

Goyal, Tarun; Walia, R. S.; Sidhu, T. S.

doi:10.1007/s00170-011-3642-6

Cited by 34 publications

(12 citation statements)

References 22 publications

(22 reference statements)

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“…Therefore, optimization of process parameters is an essential part of any spray process. Some researchers have explored optimization methods for various thermal spraying processes [34][35][36][37] such as plasma spraying and HVOF spraying. Since optimization is a crucial part of any production process, optimization methods are widely studied and they typically employ experimental methods [32], numerical analyses [25-27, 33, 35-38], or use arti cial intelligence approaches [39].…”

Section: Optimization Methods For MMC Coatingsmentioning

confidence: 99%

“…In their investigations, Goyal, et al [34][35][36] conducted several studies to optimize the surface roughness, coating thickness, and density for low-pressure cold sprayed copper coatings using the Taguchi method. The process parameters analyzed in these studies were substrate material, gas pressure and temperature, and stand-off distance.…”

Section: Optimization Methods For MMC Coatingsmentioning

confidence: 99%

“…The process parameters analyzed in these studies were substrate material, gas pressure and temperature, and stand-off distance. It was concluded that the surface roughness was most affected by gas pressure, the coating thickness by stand-off distance, and coating density by substrate material [34][35][36]. The Taguchi method is designed to only investigate the effect of process parameters on one response characteristic.…”

Section: Optimization Methods For MMC Coatingsmentioning

confidence: 99%

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Influence of Spray Parameters on the Thickness, Hardness and Porosity of low-pressure Cold Sprayed WC-Ni Coatings

Jibran

Hogan

McDonald

2021

Preprint

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In this study, a 33 full factorial design methodology was used to analyze the effects of spray parameters on the thickness, hardness, and surface porosity of low-pressure cold-sprayed WC-17Ni coatings. Three levels were selected for the spray parameters included in the design which were the powder feed rate (17.1 g/min, 21.1 g/min, and 23.7 g/min), gas temperature (475℃, 500℃, and 525℃), and the nozzle to substrate stand-off distance (3 mm, 5 mm, and 10 mm). It was found that the feed rate was the most significant parameter that affected the coating thickness. The surface porosity was most significantly affected by stand-off distance. The coating hardness was most influenced by the interaction between the feed rate and stand-off distance. An optimization study was then performed to maximize the coating thickness and hardness while minimizing the surface porosity. The optimal spray parameters (OSP) were found to be at a feed rate of 23.7 g/min, 500℃ for the carrier gas temperature, and 10 mm for the stand-off distance. The OSP yielded a coating that was 1.22 ± 0.06 mm thick, with a hardness of 364.5 ± 8.5 HV and porosity of 6.8 ± 0.6%. With a multi-parameter process, the system response is affected by both the variation in the individual parameters and the interaction of the parameters with each other. It was also concluded that the interaction between the parameters significantly affected the coating hardness. These results suggest that variation of the selected parameters produce statistically significant effects on the coating quality of WC-17Ni coatings using a low-pressure cold spray system.

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Section: Optimization Methods For MMC Coatingsmentioning

confidence: 99%

Section: Optimization Methods For MMC Coatingsmentioning

confidence: 99%

Section: Optimization Methods For MMC Coatingsmentioning

confidence: 99%

See 1 more Smart Citation

Influence of Spray Parameters on the Thickness, Hardness and Porosity of low-pressure Cold Sprayed WC-Ni Coatings

Jibran

Hogan

McDonald

2021

Preprint

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“…This approach can economically satisfy the needs of problem solving and design optimization by carrying out a small number of experiments and thus, it is possible to reduce the time and cost for the experimental investigations (Yang and Tarng 1998;Deng and Chin 2005;Bagcı and Aykut 2006;Gaitonde et al 2008;Asilturk and Akkus 2011). Because of these advantages, Taguchi method was widely used to determine the effects of process parameters on surface roughness in machining various materials out of wood, such as the optimization of cutting parameters for evaluating surface roughness in turning (Nalbant et al 2007;Gunay and Yucel 2013;Rajasekaran et al 2013), the evaluation of surface roughness in machining aluminum oxide ceramics (Chang and Kuo 2007), the optimization of cutting parameters in drilling (Tsao and Hocheng 2008;Cakıroglu and Acır 2013), the optimization of the influence of process parameters on surface roughness of aluminium alloy (Vijian and Arunachalam 2006), the optimization of surface roughness in milling operations (Benardos and Vosniakos 2002;Ghani et al 2004;Zhang et al 2007), the optimization of surface roughness of coatings (Goyal et al 2012).…”

Section: Introductionmentioning

confidence: 99%

Evaluation of process parameters for lower surface roughness in wood machining by using Taguchi design methodology

2015

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This paper presents a study of the Taguchi design method for obtaining lower surface roughness values in terms of process parameters in wood machining. The process parameters considered were feed rate, cutting depth, number of knives, annual ring (earlywood-latewood) and grit number of abrasive. The settings of the process parameters were determined by using Taguchi experimental design method. Orthogonal arrays of Taguchi and the signalto-noise (S/N) ratio were employed to find the optimal levels and to analyze the effect of process parameters on surface roughness. In addition, the Pareto ANOVA analysis was used in order to measure the influence of each process parameter on surface roughness. The results of Taguchi analysis revealed that the most significant variable on surface roughness of both beech and spruce woods by S/N ratio analysis and Pareto ANOVA analysis is the grit number of abrasive. It was also understood that the Taguchi design technique is very suitable to solve the surface quality problem regarding machining of wood species.

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“…The mathematical optimization algorithm is used to establish the mathematical relationship between the design variables and the optimization targets. The Taguchi method can effectively optimize multiparameter or multitarget machining systems and has the characteristics of simple realization, fast convergence, and global optimization [22][23][24]. However, in terms of multiobjective optimization issues, because the goals in the global analysis of the process of the weight are different, it is necessary to improve the traditional Taguchi method.…”

Section: Optimization Analysis Of the Physical And Mechanical Propertmentioning

confidence: 99%

Optimization of the Physical and Mechanical Properties of a Spline Surface Fabricated by High-Speed Cold Roll Beating Based on Taguchi Theory

Cui

et al. 2018

Mathematical Problems in Engineering

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The aim of this work is to control the physical and mechanical properties of a spline surface and achieve a reasonable choice of high-speed cold roll-beating processing parameters. The surface residual stress and surface work hardening at the indexing circle serve as the main evaluation indices of the physical and mechanical properties of the spline surface. The influence degree of the processing parameters on each evaluation index is analyzed using Taguchi theory. An optimized model for improving the Taguchi process capability index that combines Taguchi theory with entropy theory is established, and the integral process capacity index is optimized via the generalized price reduction gradient method. The results of the optimization and the verification test are implemented in a high-speed cold roll forming test for comparison. The results show that the influence of processing parameters on the physical and mechanical properties of the splash surface of the cold roll can be ordered as follows: feed rate > roll round radius > cold roll-beating speed. In addition, the spline surface physical and mechanical properties of the optimal processing parameters were obtained for the combination of a cold rolling speed of 1581 r/mm, feed rate of 42 mm/min, and roll round radius of 2 mm.

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Surface roughness optimization of cold-sprayed coatings using Taguchi method

Cited by 34 publications

References 22 publications

Influence of Spray Parameters on the Thickness, Hardness and Porosity of low-pressure Cold Sprayed WC-Ni Coatings

Influence of Spray Parameters on the Thickness, Hardness and Porosity of low-pressure Cold Sprayed WC-Ni Coatings

Evaluation of process parameters for lower surface roughness in wood machining by using Taguchi design methodology

Optimization of the Physical and Mechanical Properties of a Spline Surface Fabricated by High-Speed Cold Roll Beating Based on Taguchi Theory

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