Design Of Response Surface Methodology Research Articles

Optimization of Spray Parameters and Corrosion Properties of Plasma-Sprayed Cr2O3 Coatings Using Response Surface Methodology

In this study, the experimental design of response surface methodology was used to explore the interaction between spraying parameters to obtain an optimized process to reduce the porosity of the coating, and to prepare an excellent chromium oxide coating. The order of the single parameter affecting porosity is as follows: power > main gas > spraying distance > carrier gas flow. This study found that the spraying process with the lowest porosity of the chromium oxide coating is as follows: power of 625 W, stand-off distance of 105 mm, primary gas of 42.5 lpm, carrier gas flow of 5 lpm, and feed powder delivery rate of 35 g/min. The EDS results show that the Cr and O elements in the coating with the lowest porosity are uniformly distributed, while for the coating with the highest porosity, the elements are unevenly distributed to a certain extent, which is caused by the unevenness of the structure caused by the structure defects. The corrosion current density of chromium oxide coating VI (low porosity) is 4.34 × 10⁻⁶ A, whereas that of chromium oxide coating IV (high porosity) is 1.862 × 10⁻⁵ A. On the coating with the highest porosity, the corrosion activity is dominant, while the minimum porosity of coating is the smallest.

Synthesis of biochar from tamarind seed: experimental optimization using response surface methodology design

Abstract The present study aimed to optimize the synthesis of biochar using hydrothermal carbonization. Response surface methodology based on Box–Behnken design was utilized to optimize three experimental parameters, namely, the hydrothermal carbonization temperature, the reaction time, and the concentration of the chemical activator (H3PO4). To evaluate prepared biochars (as adsorbents), the removal of 2,4-Dichlorophenol (2,4-DCP) from wastewater was selected as a response. The results showed that, the removal of 2,4-DCP from wastewater was most significantly influenced by the hydrothermal carbonization temperature and H3PO4 concentration, whereas the reaction time effect had a lower statistical significance. The optimum synthesis conditions for the highest removal of 2,4-DCP were predicted to be H3PO4 concentration of 1.19 mol/L, a reaction time of 8 h, and a hydrothermal temperature of 187 °C. Under these optimum conditions, the model predicted removal of 2,4-DCP by model was 47.31%, while the experimental removal was 45.84%. Characterizations of the biochar synthesized at the optimum conditions showed clear improvement in terms of adsorption capacity as compared to the raw material without treatment by hydrothermal process. Graphical abstract

Optimization of Refractance Window Drying for Nutrient‐Rich Mushroom Slices: A Comparative Study With Convective and Solar Drying

ABSTRACTThis study aimed to optimize the drying parameters for mushroom slices using the refractance window drying (RWD) method, addressing the challenge of preserving both the quality and efficiency of drying in mushroom processing. By evaluating various pretreatment options and refining the drying conditions, the research sought to identify the most effective approach for enhancing the physico‐chemical parameters of the dried mushroom slices. The effects of water temperature (70°C, 80°C, and 90°C), slice thickness (2, 4, and 6 mm), and potassium metabisulphite (KMS) concentration (0.5%, 1.0%, and 1.5%) were analyzed for the same. The highest drying rate was achieved with 2 mm slices at 90°C, with rates decreasing as temperature lowered or slice thickness increased. Using a Box‐Behnken design in response surface methodology (RSM), the optimal parameters were identified as 90°C water temperature, 6 mm slice thickness, and 1.01% KMS concentration. The best results for total color difference, phenolic content, bulk density, antioxidant activity, and protein content were found in RWD samples. Compared with three‐stage convective tray drying and solar drying, RWD produced samples with superior drying rates, lower moisture, better rehydration, and higher protein and antioxidant content, especially for pretreated samples.

Decayed fruit waste juice as a sustainable medium for high-yield microbial cellulose production: optimization, characterization and bioactivity studies

In the present study, microbial cellulose (MC) was produced from decayed fruit waste juice as a fermentation medium using a consortium of microbes grown on vegetable and fruit waste as the inoculum. To optimize the MC yield, the central composite design (CCD) of response surface methodology (RSM) was applied. Four factors at five different levels were chosen in the design with a total of 26 experimental runs obtained from the CCD design. The optimal conditions were fruit waste extract (60% v/v), glucose concentration (0.75% w/v), inoculum size (5% v/v), and fermentation time (5 d) which displayed a 2.1-fold increase in MC yield of 21.719 g/L. The MC was characterized using Fourier Transform Infrared Spectroscopy, X-ray Diffraction, Scanning Electron Microscopy, and Thermogravimetric; and compared its properties to cellulose produced through other techniques. The produced MC was examined for its antioxidant properties using cyclic voltammetry (CV) displaying an anodic peak at 1.15 V. Lastly, the antimicrobial activity was tested against four different microbial strains. Among them, MC exhibited a clear zone of 7.661 ± 0.256 cm2 against E. coli. The results of this study concluded that decayed fruit waste juice is a sustainable and economical fermentation medium.

Optimasi Proses Produksi Biskuit Tinggi Protein Berbasis Soy Protein Concentrate (SPC)

Most biscuits contain an unbalanced macronutrient composition, high in carbohydrates and fat but low in protein. Additional protein sources can be incorporated to enhance their protein content. Soy protein concentrate is a highly digestible plant-based protein source. However, adding high amounts of protein can result in a harder biscuit texture, which may reduce consumer acceptance. The increased hardness caused by the natural properties of protein can be modified by altering its structure through preheating treatment. This study aimed to determine the optimal formulation based on the protein concentration and preheating temperature of soy protein concentrate to produce high-protein biscuits with good acceptability. Optimization was performed using response surface methodology (RSM) with a central composite design (CCD), evaluating biscuit hardness, stiffness, porosity, and fractal dimension. According to the RSM design, 13 experimental runs with 5 center points were conducted using Design Expert 13 software. Based on biscuit attributes such as hardness, stiffness, fractal dimension, and porosity, the optimal formulation was achieved with a protein content of 12.614% and a preheating treatment at 72.93 °C.

Wear performance of heat-treated AA6061- SiC- Gr hybrid metal matrix composites

Abstract In this work, wear response, hardness and microstructural characteristics of stir-casted
(C) AA6061- SiC- Gr hybrid metal matrix composites are analysed after exposing the samples to secondary operations like Extrusion (E), Artificially Aged (AA), Solution Treated (ST) and Solution Treated and Aged (STA). The hardness of the STA-treated samples exhibited a rise of 26.78% with finer grain and uniform particle distribution. The Central Composite Design of Response Surface Methodology has been used to formulate the DoE of wear tests with 3 factors (Load, Speed and Material) with 5 levels of load (5,10,15,20,25 N), speed (200, 400, 600, 800, 1000 rpm) and material types (C, E, AA, ST, STA). The test response in terms of Coefficient of Friction (CoF), Friction Force (FF) and Wear rate (WR) revealed the predominance of the STA process in attaining minimum wear with the combined effect of load and speed. The obtained regression equation for CoF, FF and WR are reliable to that of experimental data with an error of 13.8 ~ 10%. The two- way interactions of ANOVA have also endorsed the effect of heat treatment in attaining wear characteristics. The samples subjected to STA have exhibited high wear resistance because of the formation hybrid mixed layer on heat treatment and subsequent aging which is not possible in ST due to the absence of aging. The incomplete hybridization of AA6061 in other secondary processes is observed as unbonded particles, surface ploughing and high volume of wear debris.


Optimization of Ultrasonic-Assisted Extraction of Diene Urushiol from Lacquer Tree Leaves Using Response Surface Methodology

Lacquer trees are an important economic tree species in China, and raw lacquer is its main secondary metabolite. Polyphenolic compounds are the primary components of raw lacquer, among which diene urushiol exhibits high inhibitory activity against the reverse transcriptase of acquired immunodeficiency syndrome (AIDS). Therefore, this study established and optimized the ultrasound-assisted extraction process of diene urushiol from lacquer tree leaves. Based on single-factor experiments on the number of extractions, extraction time, extraction temperature, and solvent to solid ratio, the Box–Behnken Design response surface methodology was employed to obtain the optimal extraction process, which included three extractions, an extraction time of 55 min, an extraction temperature of 50 °C, and a solvent to solid ratio of 10:1 mL/g. Under these conditions, the content of diene urushiol was 4.56 mg/g (FW), which bore no significant difference from the theoretical value of 4.69 mg/g (FW), indicating a good model fit. Therefore, response surface methodology (RSM) can be used to optimize the extraction process of diene urushiol from lacquer leaves. This method lays a solid foundation for the comprehensive development and utilization of lacquer tree resources.

Increasing productivity for laser powder bed fusion of Ti–6Al–4V parts through increased layer thickness

Abstract Additive manufacturing (AM) has enabled the development of numerous innovative products that are now commercially available. However, its adoption for producing components traditionally manufactured using conventional methods remains limited. A significant barrier to broader industrial implementation of AM techniques, such as laser powder bed fusion (L-PBF), is their comparatively lower productivity rates, directly impacting manufacturing costs and, consequently, the adoption rate of L-PBF technology. This study examines whether modifications to L-PBF process parameters can mitigate cost-related constraints associated with production rates whilst maintaining the material properties of Ti–6Al–4V produced at standard layer thicknesses. Whilst existing research on Ti–6Al–4V processing has primarily focussed on microstructural and mechanical properties, there has been limited investigation into productivity enhancements through increased layer thicknesses beyond the conventional range of 25–60 µm. To address this gap, a series of experiments were conducted to evaluate the feasibility of increasing the layer thickness to 120 µm by modifying key process parameters, including laser power, scan speed, and hatch distance. The L-PBF parameters were varied through a response surface methodology (RSM) design of experiments (DOE) to obtain, via statistical analysis, the optimum parameters for Ti–6Al–4V at 120 μm layer thicknesses. The findings demonstrate that L-PBF systems can sustain a stable processing environment whilst operating at higher throughput levels. This was established through experimental results that show the DOE process identifying L-PBF parameters that can produce acceptable bulk density at an increased layer thickness of 120 μm. Furthermore, mechanical testing revealed that specimens printed at 120 µm exhibited comparable mechanical properties to those fabricated at the standard 60 µm thickness, achieving an average ultimate tensile strength (UTS) of 1291 MPa and 1292 MPa, and a median elongation of 9.22% and 9.74%, respectively. Post-processing techniques, including vacuum heat treatment and hot isostatic pressing (HIP), further enhanced mechanical properties, ensuring that all 120 µm specimens met or exceeded ASTM F3001-14 (Designation: F3001-14 Standard specification for additive manufacturing titanium–6 aluminum–4 vanadium ELI (extra low interstitial) with powder bed fusion. 2014. https://doi.org/10.1520/F3001-14) requirements. This study highlights the potential for increasing L-PBF productivity without compromising material performance, offering a pathway towards more cost-effective AM production for aerospace and biomedical applications.

Numerical Simulation and Optimization of a Chevron-Type Corrugated Solar Air Heater

In the present study, a numerical simulation and optimization combined approach is applied to investigate the thermal performance of a solar air heater (SAH). Numerical simulation of the solar air heater is performed based on computational fluid dynamics (CFDs) via ANSYS Fluent 2023R1 software. The solar air heater includes a corrugated absorber plate with a Chevron-type design. Present study was conducted in Al-Kharj, Saudi Arabia on August 15. The optimization process is used to enhance the thermal efficiency of the solar system. In the optimization process, several geometric parameters of the solar air heater, including the wave height and pitch length of the corrugated absorber plate and the height of the airflow channel under the absorber plate, have been evaluated. The wave height is between 10 and 20 mm, the pitch length is between 50 and 90 mm, and the channel height is between 70 and 90 mm. Therefore, the design of experiment (DOE) and response surface methodology (RSM) are utilized to estimate temperature rise and thermal efficiency. The thermal analysis shows that increasing the wave height, decreasing the pitch length, and shortening the channel height enhances both the temperature rise coefficient and the thermal efficiency.

Development of a schiff base-chitosan-vanillin/hydroxyapatite composite for effective brilliant green dye removal: Characterization, adsorption modeling, and cost analysis.

Development of a schiff base-chitosan-vanillin/hydroxyapatite composite for effective brilliant green dye removal: Characterization, adsorption modeling, and cost analysis.

Achieving 17-4 PH parts with comparable performance to high-investment technologies through a multivariable Doehlert design optimization and material extrusion

Purpose This study aims to optimize Metal Additive Manufacturing (MAM) via Material Extrusion (MEX) using desktop equipment to produce high-performance 17-4 PH stainless steel parts. This research seeks to address the underexplored extrusion process parameters that hinder optimization in this field, contributing to a deeper understanding of the MAM via the MEX process and its implications for other materials. Design/methodology/approach This study uses a quantitative approach using robust statistical methods, including Taguchi and Response Surface Methodology designs. Data was collected through a systematic investigation of the effects of process parameters on the physical and mechanical properties of the produced parts. Taguchi’s design was used to determine parameter significance, whereas a Doehlert design was used to optimize responses, focusing on layer adhesion and porosity reduction. Findings The results reveal that the optimized extrusion process parameters significantly improved the tensile modulus (198.2±11.9 GPa), tensile strength (977.2±31.8 MPa) and Vickers hardness (287±7 HV100). These findings confirm the efficacy of the methodology, demonstrating that superior mechanical properties can be achieved using desktop equipment. Comparative analysis with professional-grade equipment supports the feasibility of producing cost-effective, high-performance metal parts. Originality/value This research offers a novel approach to optimizing MAM via MEX, particularly for stainless steel alloys. The findings contribute valuable insights that extend the current understanding of MEX processes, highlighting the potential for this approach to advance MAM capabilities for industrial applications. This study also identifies areas for future research and potential practical applications, contributing to the broader field of MAM.

Study on Mechanical Properties and Hydration Characteristics of Bauxite-GGBFS Alkali-Activated Materials, Based on Composite Alkali Activator and Response Surface Method

To address the limitations in determining the amount of activator and optimizing the mix proportion during the preparation of bauxite tailings (BX)-based alkali-activated materials (AAMs), as well as the insufficient research on the interactions of multiple factors, this study aims to synthesize and optimize composite cementitious materials with BX and granulated blast furnace slag (GGBFS) as precursors via response surface methodology and central composite design (RSM-CCD). The optimal alkali activator proportion and slag content for alkali-activated, bauxite tailing, powder slag cementitious materials were investigated. A series of tests, including XRD, FTIR, TG-DSC, and SEM–EDS, were used for analysis to further investigate the effects of the alkali activator dosage on the mechanical properties and the influence of the slag content on the hydration products and microstructure. The results show that the optimal composition of alkali-activated bauxite tailings-based cementitious material is 35% slag content, 4% alkali content, a water glass modulus of 1.3, and a water–solid ratio of 0.32. The relationship model between the activator parameters and compressive strength fits well, with model determination coefficients of 0.9803 for f3c and 0.9789 for f28c. The identified hydration products were mainly C-S-H and C-(N)-A-S-H gels in the form of SiQ3 and SiQ4 tetrahedra. The SEM–EDS results show that the incorporation of slag changes the silicon–aluminum ratio of the system, promoting an increase in the content of hydration products and increasing the complexity and density of the structure. GGBFS also has a micro-aggregate filling effect and a nucleation effect, which improve the distribution of hydration products. This study demonstrates the significant potential of BX in the preparation of cementitious materials, which contributes to the sustainable development of the construction industry.

Advanced extraction of Glycyrrhiza glabra root extract using a combined ultrasonic and cold plasma reactor

Liquorice (Glycyrrhiza glabra L.) root extract has been used as a natural medicine and sweetener for a long time in many parts of the world. As a result, there has been a considerable emphasis on developing efficient and environmentally friendly methods for extracting bioactive components from Liquorice root. This work aims to examine extracting extract from Liquorice root using a combined ultrasonic-cold plasma reactor to elevate the extraction efficiency. Different parameters, including extraction time, ultrasonic power, and the argon-to-air ratio, were investigated using the Response Surface Methodology (RSM) and Box-Behnken design to raise extract quality. The total phenol and flavonoid content and antioxidant activity were calculated to evaluate this approach, and Glycyrrhizic acid content was quantified by HPLC (High-performance liquid chromatography). Results showed that combining ultrasonic-cold plasma extraction greatly raised the yield of extract and bioactive components compared to conventional maceration and single-method methods. Particularly, The content of total phenol 10.23, 15.96, and 13.29%, total flavonoid content 21.47, 22.19, and 42.41%, and Glycyrrhizic acid 10.84%, 12.38%, and 15.89% increased by ultrasonic, cold plasma, and combined ultrasonic-cold plasma technique, respectively, compared to the maceration technique. Optimization of different extraction techniques showed that the best extract quality came from a mix of ultrasonic power, plasma composition, and extraction time. This study demonstrates that the combined ultrasonic-cold plasma technique is effective and efficient, and this technology has the potential for a new extraction method to present a more sustainable and effective substitute for premium Liquorice extracts for medicinal and commercial uses.

Implementation of RSM and ANN optimization approach for the valorization of agro-wastes to renewable plastic precursor FDCA over non-precious bimetal oxide functionalized heterogeneous catalyst.

Implementation of RSM and ANN optimization approach for the valorization of agro-wastes to renewable plastic precursor FDCA over non-precious bimetal oxide functionalized heterogeneous catalyst.

Optimization of recombinant neurturin expression in Escherichia coli using response surface methodology.

Neurturin, a neurotrophic growth factor, has been identified as a potential treatment or reversal agent for neurodegenerative conditions. Although Escherichia coli is an appropriate host for recombinant protein expression, the production of proteins with disulfide bonds, such as neurturin, in this strain is frequently accompanied by the formation of inclusion bodies. In this study, the Rosetta-gami strain, which is well-suited for the accurate formation of disulfide bonds was employed for the soluble production of neurturin. Response surface methodology (RSM) was also used to investigate the effects ofIPTG concentration, post-induction time and temperature on the soluble production of neurturin. The results showed that the highest yield of neurturin production occurred in the presence of 0.8mM of IPTG after 5.5h at 26 ºC. Fractional Factorial Design was used in the subsequent stage to screen the effects of culture medium components on the protein production. The best concentrations of yeast extract, tryptone and MgSO4 to have a significant effect on total protein concentration were determined by RSM design to be 15g/l for both tryptone and yeast extract and 2.2g/l for MgSO4. Finally, an experiment was carried out under optimized conditions to evaluate the yield of the process. The results demonstrated a notable enhancement in neurturin production following optimization, with an increase of 8.6-fold compared to the normal condition.

Efficient Removal of Cu(II) from Wastewater Using Chitosan Derived from Shrimp Shells: A Kinetic, Thermodynamic, Optimization, and Modelling Study

Chitosan was hydro-thermally extracted from grey shrimp carapaces and characterized using various techniques (degree of deacetylation (DD), viscosity, thermogravimetric analysis (TGA), scanning electron microscopy (SEM), and surface area analysis (BET)). It was then used for Cu(II) removal in a batch system, achieving a maximum capacity of 89 mg/g under standard conditions. Both pseudo-first-order and pseudo-second-order nonlinear kinetic models described the adsorption of Cu(II) ions on chitosan well, with a better fit of the pseudo-first-order model at low concentrations, while the equilibrium data suggested that the Langmuir model was suitable for describing the adsorption system, with a maximum adsorption capacity of 123 mg/g. A response surface methodology and central composite design were used to optimise and evaluate the effects of six independent parameters: initial Cu(II) concentration, pH, chitosan concentration (S/L), temperature (T), contact time (t), and NaCl concentration on the adsorption efficiency of Cu(II) by the synthesised chitosan. The proposed model was confirmed to accurately describe the phenomenon within the experimental range, achieving an R2 value of 1. ANOVA indicated that the initial concentrations of Cu(II) and chitosan concentration (S/L) were the most significant factors, while the other variables had no significant effect on the process. The adsorption capacity of Cu(II) onto the prepared chitosan was also optimised and modelled using artificial neural networks (ANNs). The maximum amount, qmax = 468 mg·g−1, shows that chitosan is a highly effective adsorbent, chelating and complexing for copper ions.

Statistical Optimization of Exopolysaccharide and Biomass Production by Mangrove Fungi Fusarium equiseti ANP2 and its Potential Application as Bioemulsifier and Chelator.

The rationale of the study is to explore the bio functional industrial potential and optimized culture conditions of a Manno glucan heteropolysaccharide MF-1 (purified EPS fraction) produced by a newly discovered mangrove derived fungi Fusarium equiseti ANP2, isolated from the Krishna River delta mangrove sediments. Response surface methodology (RSM) was employed to optimize fungal EPS and Biomass production, achieving a significant 1.4-fold increase to 6.94g/L in EPS yield and a 2.1-fold increase in biomass production. RSM identified optimal levels of glucose, NH₄NO₃, NaCl, leucine, temperature, and pH, while minimizing the required glucose and nitrogen content compared to conventional methods. Notably, MF-1 exhibited promising emulsification potential (69.5% n-hexadecane emulsification), suggesting its prospective role as a novel emulsifier, particularly for n-hexadecane-based applications. Additionally, MF-1 also displayed a chelating activity for Fe2⁺ ions, suggesting its applicability as a natural chelating agent. The current study optimized the EPS production using RSM design and explored its potential for industrial applications as emulsification and chelating properties of the purified EPS fraction. Future research could explore the structural modifications of the fungal EPS to enhance its functionalities and delve deeper into the mechanisms governing EPS and biomass for large-scale, sustainable industrial production.

Parameter Optimization and Experimental Study of Drum with Elastic Tooth Type Loss-Reducing Picking Mechanism of Pepper Harvester

To reduce harvest losses of a pepper harvester with a drum of elastic tooth type picking mechanism, this paper proposes an optimization method using AHP (Analytic Hierarchy Process) and RSM (Response Surface Methodology), thereby identifying the optimal harvesting parameters. Based on Hertz’s contact theory and projectile motion theory, dynamic and kinematic models were established for the picking and casting stage. Key parameters influencing harvest loss were identified as drum rotational speed, operating speed, and tooth spacing. A simulation model was constructed, and solved within LS-DYNA of ANSYS Workbench. A Box–Behnken design in RSM was employed to investigate the effects of drum rotational speed, operating speed, and tooth spacing on the picking rate, breakage rate, and loss rate. The optimal parameters, obtained through RSM optimization after AHP weighting, were determined to be a drum rotational speed of 182 r/min, an operating speed of 0.42 m/s, and a tooth spacing of 40 mm. A test bench was designed for validation, with simulation results deviating from experimental results by less than 5%. With optimized parameters, the picking rate increases from 89.73% to 95.13%, the breakage rate decreases from 3.21% to 2.66%, and the loss rate decreases from 5.16% to 3.95%. This study provides a theoretical foundation and practical reference for optimizing the drum with elastic tooth type picking mechanism in pepper harvesters.

Optimal hydraulic engine mount parameters using design of experiment (DoE) and response surface methodology

Abstract This study experimentally investigated the parameters such as dynamic hardening, inertia track cross-sectional area, decoupler hardness, and fluid volume affecting the damping properties of passive hydraulic engine mounts. Two levels were determined for these parameters, and the full factorial design of experiment (DoE) was created. According to the DoE, hydraulic engine mounts with various design configurations were assembled and tested. Based on the test results, a response surface was created in the Hyperstudy software, and the optimal parameters were obtained via the surface for the desired hydraulic mount performance. Another mount close to the optimum design configuration was then analyzed by the Hyperstudy, and the analysis results were confirmed with the test results. It was observed that the experimental and analysis results were consistent. As a result, it has been demonstrated that the mount parameters can be decided with the response surface generated with the DoE. So, both time and cost advantages can be achieved by eliminating trial and error in production.

Maximizing the production of total reducing sugars from sugarcane bagasse using ultrasound‐assisted acid hydrolysis based on response surface methodology approach

AbstractThe depletion of fossil fuels and the associated environmental impact necessitate the development of sustainable energy sources as well as feedstocks for value added chemicals. Lignocellulosic biomass, particularly sugarcane bagasse (SCB), is a promising feedstock for various industrial processes and products with the total reducing sugars (TRS) as one of the valuable intermediates. The current study focuses on maximizing TRS production from sugarcane bagasse using ultrasound‐assisted acid hydrolysis. The Box–Behnken design of response surface methodology was employed to determine the best conditions for maximizing TRS concentration, with the study involving five independent variables as time, ultrasonic power, duty cycle, temperature, and acid loading. The statistical analysis predicted the best operating parameters as time of 82.77 min, ultrasonic power of 124.03 W, 60.95% duty cycle, temperature of 61°C, and acid concentration of 3.44%, resulting in the highest TRS concentration of 3.49 mg/mL. Experimental data and statistical analysis validated the quadratic model's predictive capability, demonstrating its practical applicability in enhancing TRS production efficiency. Overall, the work has demonstrated an effective method of using delignified biomass for maximizing the yield of reducing sugars based on detailed study of the effect of operating parameters.