Title: Optimisation and sensitivity analysis of atmospheric plasma spraying parameters to minimise porosity in alumina coatings on AZ31B magnesium alloy

Authors: D. Thirumalaikumarasamy; K. Shanmugam; V. Balasubramanian

Addresses: Department of Manufacturing Engineering, Annamalai University, Annamalainagar – 608 002, Chidambaram, Tamil Nadu, India ' Department of Manufacturing Engineering, Annamalai University, Annamalainagar – 608 002, Chidambaram, Tamil Nadu, India ' Center for Materials Joining Research (CEMAJOR), Department of Manufacturing Engineering, Annamalai University, Annamalainagar – 608 002, Tamil Nadu, India

Abstract: In this investigation, an attempt has been made to establish an empirical relationship and is developed to predict the porosity level of alumina coated AZ31B magnesium alloy by incorporating process parameters such as power, stand-off distance and powder feed rate. The porosity of alumina coatings were evaluated by the digital image analysis method. The experiments were conducted based on a three factor, five level, central composite rotatable design matrix with full replications technique. The developed empirical relationship can be effectively used to predict the porosity level of alumina coatings at 95% confidence level. Response surface methodology (RSM) was applied to optimise the atmospheric plasma spraying parameters to attain the minimum porosity level. The results indicate that the input power has the greatest influence on porosity level, followed by stand-off distance and powder feed rate.

Keywords: atmospheric plasma spraying; APS; optimisation; response surface methodology; RSM; alumina coatings; porosity level; sensitivity analysis; magnesium alloys; input power; stand-off distance; powder feed rate.

DOI: 10.1504/IJCMSSE.2013.059141

International Journal of Computational Materials Science and Surface Engineering, 2013 Vol.5 No.4, pp.346 - 369

Received: 21 Jan 2013
Accepted: 06 Nov 2013
Published online: 21 Jun 2014 *

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