Predicting the Deposition Efficiency of Plasma Sprayed Alumina Coatings on AZ31B Magnesium Alloy by Response Surface Methodology

Abstract

Plasma sprayed ceramic coatings are successfully employed in many industrial applications, where high wear and corrosion resistance with thermal insulation are needed. Plasma spray parameters such as power, stand-off distance and powder feed rate have significant influence on coating characteristics like deposition efficiency. This paper presents the use of statistical techniques specially response surface methodology (RSM), analysis of variance, and regression analysis to develop empirical relationships to predict deposition efficiency of plasma sprayed alumina coatings on AZ31B magnesium alloy. The developed empirical relationships can be efficiently used to predict deposition efficiency of plasma sprayed alumina coatings at 95% confidence level. Response graphs and contour plots were constructed to identify the optimum plasma spray parameters to attain maximum deposition efficiency in alumina coatings. Further, correlating the spray parameters with coating properties permits the identification of characteristics regime to achieve desired quality of coatings.