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Better Quality Control: Stochastic Approaches to Optimize Properties and Performance of Plasma-Sprayed Coatings

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Abstract

Statistical design of experiment (SDE) methodology applied to design and performance testing of plasma-sprayed coatings follows an evolutionary path, usually starting with classic multiparameter screening designs (Plackett-Burman), and progressing through factorial (Taguchi) to limited response surface designs (Box-Behnken). Modern designs of higher dimensionality, such as central composite and D-optimal designs, will provide results with higher predictive power. Complex theoretical models relying on evolutionary algorithms, and application of artificial neuronal networks (ANNs) and fuzzy logic control (FLC) allow estimating the behavior of the complex plasma spray environment through validation either by key experiments or first-principle calculations. In this review, paper general principles of SDE will be discussed and examples be given that underscore the different powers of prediction of individual statistical designs. Basic rules of ANN and FLC will be briefly touched on, and their potential for increased reliability of coating performance through stringent quality control measures assessed. Salient features will be reviewed of studies performed to optimize thermal coating properties and processes reported in the pertinent literature between 2000 and the present.

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Notes

  1. Note that the factorial designs are considered to have a "cuboidal" or "hypercube" factor space whereas the true response surface designs have a "spherical" factor space.

  2. These linguistic terms are at least semantically akin to ‘discrete’ variables in the much less involved screening designs of Plackett-Burman type.

  3. It should be mentioned that adhesion of plasma-sprayed coatings is not just a function of coating thickness which controls the residual stress level, but other factors such as splat cohesion, substrate roughness, temperature of the substrate, properties of the bond coats, level of impurities and degree of oxidation play likewise important roles.

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Acknowledgments

The author of this review paper is indebted to several colleagues including Christian Coddet (Belfort, France), Thomas Coyle (Toronto, Canada), Rogerio Lima (Boucherville, Canada), Sanjay Sampath (Stony Brook, USA), and P. Saravanan (Coimbatore, India) for providing access to their published work. Thanks are also due to Hans D. Lehmann (Görlitz, Germany) for bibliographical assistance.

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  1. Professor Emeritus of Applied Mineralogy and Materials Science, Am Stadtpark 2A, 02826, Görlitz, Germany

    Robert B. Heimann

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Heimann, R.B. Better Quality Control: Stochastic Approaches to Optimize Properties and Performance of Plasma-Sprayed Coatings. J Therm Spray Tech 19, 765–778 (2010). https://doi.org/10.1007/s11666-009-9385-3

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