Development of the process index for NiCrAlY coatings with the Mettech Axial III™ System

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DOIResolve DOI: http://doi.org/10.1007/s11665-012-0326-9
AuthorSearch for: ; Search for: ; Search for: ; Search for:
TypeArticle
Journal titleJournal of Materials Engineering and Performance
ISSN1059-9495
1544-1024
Volume22
Issue3
Pages713722; # of pages: 10
Subjectcracks; Mettech Axial III; oxides; pores; process index; regression equations; spray parameters; Taguchi arrays; unmelted particles
AbstractNiCrAlY coatings were deposited using the Mettech Axial III™ plasma spray system. The microstructural features of the coatings, such as the porosity, crack, un-melted particle, and oxide content, were analyzed to investigate the effects of the spray process parameters on these features. Two Taguchi arrays were used to examine the effects of the spray process parameters such as powder size, ratio of (H2 + N2) gas flow over total gas flow, current, spray-gun nozzle size, and spray distance, on the microstructural features of the coatings. The results from statistical analysis are used to create regression equations to predict the microstructural features of the coatings. In the regression equations, a process index (PI) is used as a complex variable incorporating a number of process parameters. The results from an additional set of experiments are used to verify the validity of the regression equations. It has been demonstrated that the equations correlate well with the results from the subsequent set of experiments. It is concluded from this study that the PI can be used to categorize coating qualities with respect to the extent of crack, porosity, unmelted particle, and oxide content in the coating. These equations can also serve as an initial step in developing process parameters by means of the Mettech Axial III™ System.
Publication date
LanguageEnglish
AffiliationAerospace; National Research Council Canada
Peer reviewedYes
Identifier326
NPARC number21268425
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Record identifierdb51c764-cffa-4066-ab76-0dce0c0856bc
Record created2013-07-11
Record modified2016-05-09
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