| Abstract: |
High Velocity Oxy Fuel (HVOF) and Plasma Thermal Spray are effective solutions in the enhancement of surfaces when subjected to hostile environments. However these Thermal Spray processes are complex and can involving numerous process parameters, which if one was to fully optimize a particular process and coating powder, using a One Variable At a Time (OVAT) technique, the methodology would prove costly in terms of time and expense and interaction effects would be missed. As a result of this complexity, the process property structure relationship is often poorly understood and under optimised. In this study, a Design of Experiment (DOE) methodology was used to demonstrate the effects of both HVOF and Plasma spray process parameters (Gas Flow Rate(s), Powder Feed Rate, Spray Distance, Carrier Gas Flow Rate, Current, depending on the respective process) on various properties of typical Thermal Spray coatings. The analysis was carried out using a case study for each process and introduces the methodology behind a fractional factorial design. The responses investigated and DOE models, were related in terms of ANOVA analysis and single/interactive parameter effects, along with desirability optimization, which will provide future Thermal Spray users with an experimental methodology to statistically improve coating performance.
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