Influences of atmospheric plasma spraying parameters on the porosity level of alumina coating on AZ31B magnesium alloy using response surface methodology

The main problem faced in the plasma spraying is the selection of optimum combination of input variables for achieving the required qualities of coating. This problem can be solved by the development of relationship between the process parameters (input power, stand-off distance and powder feed rate) and the coating quality characteristics (porosity,) by response surface methodology. This article highlights the use of response surface methodology by designing a three-factor five level central composite rotatable design matrix with full replication for planning, conduction, execution, and development of empirical relationship. Alumina coating was deposited on AZ31B magnesium alloy using atmospheric plasma spraying process by varying parameters such as power, stand-off distance and powder feed rate. Further, response surface methodology was used for the selection of optimum plasma spraying parameters to achieve desired quality of alumina coating.