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.
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