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Multiobjective Optimization of Atmospheric Plasma Spray Process Parameters to Deposit Yttria-Stabilized Zirconia Coatings Using Response Surface Methodology

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Abstract

Atmospheric plasma spraying is used extensively to make Thermal Barrier Coatings of 7-8% yttria-stabilized zirconia powders. The main problem faced in the manufacture of yttria-stabilized zirconia coatings by the atmospheric plasma spraying process is the selection of the optimum combination of input variables for achieving the required qualities of coating. This problem can be solved by the development of empirical relationships between the process parameters (input power, primary gas flow rate, stand-off distance, powder feed rate, and carrier gas flow rate) and the coating quality characteristics (deposition efficiency, tensile bond strength, lap shear bond strength, porosity, and hardness) through effective and strategic planning and the execution of experiments by response surface methodology. This article highlights the use of response surface methodology by designing a five-factor five-level central composite rotatable design matrix with full replication for planning, conduction, execution, and development of empirical relationships. Further, response surface methodology was used for the selection of optimum process parameters to achieve desired quality of yttria-stabilized zirconia coating deposits.

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Acknowledgments

The authors wish to express their sincere thanks to the Department of Science and Technology (DST), Govt. of India, New Delhi for the financial support extended to carry out this investigation through the sponsored fast-track scheme for young scientists—R&D project No. SR/FT/ETA-01/2009. The help provided by Mr. A. K. Lakshminarayanan (PhD Scholar, the Dept. of Manufacturing Engg., Annamalai University) in the statistical part of this article is greatly acknowledged.

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  1. Department of Manufacturing Engineering, Annamalai University, Annamalai Nagar, 608 002, Tamilnadu, India

    C. S. Ramachandran & V. Balasubramanian

  2. Plasma Spray Technologies Section (PSTS), Laser and Plasma Technology Division (L&PTD), Bhabha Atomic Research Centre (BARC), Anu Shakthi Nagar, Trombay, Mumbai, 400 085, Maharashtra, India

    P. V. Ananthapadmanabhan

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  1. C. S. Ramachandran
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Correspondence to C. S. Ramachandran.

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Ramachandran, C.S., Balasubramanian, V. & Ananthapadmanabhan, P.V. Multiobjective Optimization of Atmospheric Plasma Spray Process Parameters to Deposit Yttria-Stabilized Zirconia Coatings Using Response Surface Methodology. J Therm Spray Tech 20, 590–607 (2011). https://doi.org/10.1007/s11666-010-9604-y

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