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Optimization of Ni60A Coating Quality by Supersonic Plasma Spraying Based on Response Surface Methodology

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Abstract

The use of advanced thermal spray technology for surface modification of aluminum alloy parts for automobiles can greatly improve the surface properties and service life of the parts while saving resources and reducing environmental pollution. In this paper, a Ni60A coating was prepared on the surface of aluminum alloy 109 (ZL109) by supersonic plasma spraying (HEPJet). The spraying process parameters were optimized based on the response surface methodology (RSM). The effects of the main factors such as spraying power, spraying distance, and Ar flow rate on the porosity and microhardness of the coating were analyzed by the Box–Behnken method (BBD). The response surface of the porosity and microhardness of the coating was constructed by establishing the appropriate mathematical model. The response surface of porosity and microhardness of the coating was constructed by establishing a relevant mathematical model. The results show that the established mathematical model is reliable, and the spray power has the greatest influence on the porosity and microhardness of the coating. The optimal porosity and microhardness of the coating predicted by the model are 0.85% and 971.1HV0.1, respectively, which is close to the experimental results. The porosity and microhardness of the coating measured by the experiment are 0.87% and 959.8HV0.1, respectively. The coatings prepared with optimal parameters have good compactness, small porosity, and high hardness.

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Acknowledgments

This work was supported by the Foundation of Research Project of China (50904010201)

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Author notes

  1. Sheng Zhu

    Present address: National Key Laboratory for Remanufacturing, Beijing, 100072, China

Authors and Affiliations

  1. School of Automotive and Traffic Engineering, Jiangsu University of Technology, Chang Zhou, 213001, China

    Bing-yuan Han, Jia-jie Chu, Meng-qi Cong, Fang-fang Cui & Wei-xing Hang

  2. National Key Laboratory for Remanufacturing, Beijing, 100072, China

    Bing-yuan Han, Wen-bo Du & Ke-bing Zhou

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  1. Bing-yuan Han
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Han, By., Chu, Jj., Du, Wb. et al. Optimization of Ni60A Coating Quality by Supersonic Plasma Spraying Based on Response Surface Methodology. J Therm Spray Tech 32, 1596–1610 (2023). https://doi.org/10.1007/s11666-023-01580-8

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