Effects of plasma spray parameters on TiO2-coated mild steel using design of experiment (DoE) approach

S. M. Forghani, Mariyam Jameelah Ghazali, Andanastuti Muchtar, A. R. Daud, N. H N Yusoff, Che Husna Azhari

Research output: Contribution to journalArticle

18 Citations (Scopus)

Abstract

In this study, a design of experiment (DoE) method was utilised to identify the effect of air plasma spray (APS) parameters on several main properties of titanium dioxide (TiO2) coatings. Titanium dioxide (titania) feedstocks with sizes ranging from 10 μm to 45 μm were sprayed onto the mild steel substrates with different plasma spraying parameters. A 24 full factorial design was used to investigate the effects of four varying principal parameters at two levels, namely, the plasma power (20 and 40 KW), the powder feed rate (6 and 22 g/min), the scanning speed (0.2 and 0.5 m/s), and the number of cycles (10 and 20), on four important properties of coatings; microhardness, thickness/cycle, deposition efficiency (DE), and porosity. The results showed that one the most important factor in affecting all responses was the plasma power. It strongly affected the hardness and the porosity which had a primary effect on the thickness/cycle and the DE values. In contrast, the interaction of the powder feed rate and the scanning speed had a negative effects on both thickness/cycle and DE. The number of cycles has no profound effect on the considered responses; it can only be used as a factor to achieve different coating thicknesses. To conclude, a plasma power of 30 kW with a low level of powder feed rate of 6 g/min and 0.5 m/s of scanning speed is most preferable to optimise TiO2 coating deposition on mild steels.

Original languageEnglish
Pages (from-to)3121-3127
Number of pages7
JournalCeramics International
Volume39
Issue number3
DOIs
Publication statusPublished - Apr 2013

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Design of experiments
Carbon steel
Powders
Plasmas
Coatings
Scanning
Titanium dioxide
Porosity
Plasma spraying
Microhardness
Feedstocks
Titanium
Hardness
Substrates
Air
titanium dioxide

Keywords

  • B. Surfaces
  • C. Mechanical properties
  • D. TiO
  • E. Structural applications

ASJC Scopus subject areas

  • Ceramics and Composites
  • Process Chemistry and Technology
  • Electronic, Optical and Magnetic Materials
  • Surfaces, Coatings and Films
  • Materials Chemistry

Cite this

Effects of plasma spray parameters on TiO2-coated mild steel using design of experiment (DoE) approach. / Forghani, S. M.; Ghazali, Mariyam Jameelah; Muchtar, Andanastuti; Daud, A. R.; Yusoff, N. H N; Azhari, Che Husna.

In: Ceramics International, Vol. 39, No. 3, 04.2013, p. 3121-3127.

Research output: Contribution to journalArticle

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AB - In this study, a design of experiment (DoE) method was utilised to identify the effect of air plasma spray (APS) parameters on several main properties of titanium dioxide (TiO2) coatings. Titanium dioxide (titania) feedstocks with sizes ranging from 10 μm to 45 μm were sprayed onto the mild steel substrates with different plasma spraying parameters. A 24 full factorial design was used to investigate the effects of four varying principal parameters at two levels, namely, the plasma power (20 and 40 KW), the powder feed rate (6 and 22 g/min), the scanning speed (0.2 and 0.5 m/s), and the number of cycles (10 and 20), on four important properties of coatings; microhardness, thickness/cycle, deposition efficiency (DE), and porosity. The results showed that one the most important factor in affecting all responses was the plasma power. It strongly affected the hardness and the porosity which had a primary effect on the thickness/cycle and the DE values. In contrast, the interaction of the powder feed rate and the scanning speed had a negative effects on both thickness/cycle and DE. The number of cycles has no profound effect on the considered responses; it can only be used as a factor to achieve different coating thicknesses. To conclude, a plasma power of 30 kW with a low level of powder feed rate of 6 g/min and 0.5 m/s of scanning speed is most preferable to optimise TiO2 coating deposition on mild steels.

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