Application of response surface methodology for robustness of responses of yttria stabilized zirconia coatings

Abstract

This article presents an application of surface response methodology and the design of an experiment to develop robust wear-resistant characteristics for partially stabilized zirconia coatings in plasma spraying processes. In this study, the effects of control factors on the porosity percentage and wear resistance responses are evaluated and discussed. The relationship between the responses with significant factors is established. By employing a response surface methodology, a series of mathematical regression models can be efficiently performed. These response models are applied to analyze the response surface contours and surface plots to estimate all responses simultaneously for developing a better deposition performance for plasma spraying processes. The experimental results obtained show that using an experimental design strategy with a quadric model proposed is used not only for predicted optimal process parameters for achieving the desired quality but also for process optimization. Several response plots were generated to examine parameter effects on the response profiles. The microstructures of the worn surface were examined and revealed a dense lamella and highly anisotropic with a slight plastic deformation through the optimal conditions.