| Abstract: |
The solution precursor plasma spraying (SPPS) process, in which a solution precursor of the desired resultant material is fed into a plasma jet by atomizing gas or high pressure, was developed in the 1990?s and has been studied extensively since then. Because of the complexity of the SPPS process and the large number of processing parameters, it is difficult to investigate the effect of each parameter on the two important properties, i.e. deposition efficiency and coating microstructure separately. In this project, a factorial statistical experimental design was used to select the processing parameters which have significant effects on deposition efficiency and the porosity of the fabricated coatings. The processing parameters investigated include: 1) Arc voltage, 2) Current , 3) Solute flow rate, 4) Solution concentration, 5) Distance between nozzle and gun, 6) Secondary plasma gas, 7) Stand off distance, 8) Atomizing gas, 9) Atomizing gas pressure, and 10) post-deposition heat treatment temperature. The effects of the selected parameters were analyzed, and the SPPS process was successfully optimized by use of a second order statistical model, the small central composite design.
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