全部 标题 作者
关键词 摘要

OALib Journal期刊
ISSN: 2333-9721
费用：99美元
投递稿件

查看量下载量

相关文章

更多...

Parameter Optimization of Amalgamated Al2O3-40% TiO2 Atmospheric Plasma Spray Coating on SS304 Substrate Using TLBO Algorithm

DOI: 10.4236/jsemat.2016.63009, PP. 89-105

Keywords: Atmospheric Plasma Spray (APS) Coating, SS304 Steel, Teaching Learning Based Optimization (TLBO), Design of Experiments (DoE), Analytic Hierarchy Process (AHP), Al2O2-40% TiO3

Full-Text   Cite this paper   Add to My Lib

Abstract:

SS304 is a commercial grade stainless steel which is used for various engineering applications like shafts, guides, jigs, fixtures, etc. Ceramic coating of the wear areas of such parts is a regular practice which significantly enhances the Mean Time Between Failure (MTBF). The final coating quality depends mainly on the coating thickness, surface roughness and hardness which ultimately decides the life. This paper presents an experimental study to effectively optimize the Atmospheric Plasma Spray (APS) process input parameters of Al2O3-40% TiO2 ceramic coatings to get the best quality of coating on commercial SS304 substrate. The experiments are conducted with a three-level L18 Orthogonal Array (OA) Design of Experiments (DoE). Critical input parameters considered are: spray nozzle distance, substrate rotating speed, current of the arc, carrier gas flow and coating powder flow rate. The surface roughness, coating thickness and hardness are considered as the output parameters. Mathematical models are generated using regression analysis for individual output parameters. The Analytic Hierarchy Process (AHP) method is applied to generate weights for the individual objective functions and a combined objective function is generated. An advanced optimization method, Teaching-Learning-Based Optimization algorithm (TLBO), is applied to the combined objective function to optimize the values of input parameters to get the best output parameters and confirmation tests are conducted based on that. The significant effects of spray parameters on surface roughness, coating thickness and coating hardness are studied in detail.

 References

[1]  Ramachandran, C.S., Balasubramanian, V., Ananthapadmanabhan, P.V. and Viswabaskaran, V. (2012) Influence of Intermixed Interfacial Layers in the Thermal Cycling Behaviour of Atmospheric Plasma Sprayed Lanthanum Zirconate Based Coatings. Ceramics International, 3895, 4081-4096.
[2]  Yong, P.J., Hyung, Y.S., Jong, D.K. and Chung, G.K. (2013) Experimental Analysis of Coating Layer Behaviour of Al-Si-Coated Boron Steel in a Hot Bending Process for IT Applications. International Journal of Advanced Manufacturing Technology, 67, 1693-1700.
http://dx.doi.org/10.1007/s00170-012-4602-5
[3]  Parisa, F., Thomas, F., Molly, M. and Radovan, K. (2015) Comparative Study of the Slurry Erosion Behaviour of Laser Cladded Ni-WC Coating Modified by Nanocrystalline WC and La2O3. International Journal for Advanced Manufacturing Technology, 79, 1607-1621.
http://dx.doi.org/10.1007/s00170-015-6936-2
[4]  Zalnezhad, E., Ahmed, A.D.S. and Hamdi, M. (2013) Optimizing the PVD TiN Thin Film Coating’s Parameters on Aerospace AL7075-T6 Alloy for Higher Coating Hardness and Adhesion with Better Tribological Properties of the Coating Surface. International Journal of Advanced Manufacturing Technology, 64, 281-290.
http://dx.doi.org/10.1007/s00170-012-4022-6
[5]  Zalnezhad, E., Ahmed, A.D.S. and Hamdi, M.A. (2013) Fuzzy Logic Based Model to Predict Surface Hardness of Thin Film TiN Coating on Aerospace. International Journal of Advanced Manufacturing Technology, 68, 415-423.
http://dx.doi.org/10.1007/s00170-013-4738-y
[6]  Toko, T., Danuta, S., Kiyotaka, M., Munekazu, O. and Maciej, P. (2015) Sensitivity Analysis for Thickness Uniformity of Al Coating Layer in Extrusion of Mg/Al Clad Bar. International Journal of Advanced Manufacturing Technology, 80, 507-513.
http://dx.doi.org/10.1007/s00170-015-7019-0
[7]  Amir, H.P., Ehsan, G., Mehrdad, N., Kamyar, S., Amir, H.J. and Reza, T. (2015) Development Empirical-Intelligent Relationship between Plasma Spray Parameters and Coating Performance of Yttria-Stabilized Zirconia. International Journal of Advanced Manufacturing Technology, 76, 1031-1045.
http://dx.doi.org/10.1007/s00170-014-6212-x
[8]  Binu, C.Y. and Ramamoorthy, B. (2008) Characterization of DC Magnetron Sputtered Diamond-Like Carbon (DLC) Nano Coating. International Journal of Advanced Manufacturing Technology, 38, 705-717.
http://dx.doi.org/10.1007/s00170-007-1131-8
[9]  Bor, T.L., Ming, D.J. and Chou, J.H. (2007) Using Response Surface Methodology with Response Transformation in Optimizing Plasma Spraying Coatings. International Journal of Advanced Manufacturing Technology, 34, 307-315.
http://dx.doi.org/10.1007/s00170-006-0599-y
[10]  Wang, W.M., Li, D.Y., Hu, J., Peng, Y.H., Zhang, Y.S. and Li, D.Y. (2005) Numerical Simulation of Fluid Flow and Heat Transfer in a Plasma Spray Gun. International Journal of Advanced Manufacturing Technology, 26, 537-543.
http://dx.doi.org/10.1007/s00170-004-2334-x
[11]  Azarmi, F., Coyle, T., Mostaghimi, J. and Pershin, L. (2009) A New Approach to Develop High Temperature Foam Core Sandwich Structures Using Air Plasma Spraying. International Journal of Advanced Manufacturing Technology, 44, 900-905.
http://dx.doi.org/10.1007/s00170-008-1913-7
[12]  Saravanan, P., Selvarajan, V., Joshi, S.V. and Sundararajan, G. (2001) Experimental Design and Performance Analysis of Alumina Coatings Deposited by a Detonation Spray Process. Journal of Applied Physics, 34, 131-140.
http://dx.doi.org/10.1088/0022-3727/34/1/320
[13]  Yugeswaran, S., Selvarajan, V., Vijay, M., Ananthapadmanabhan, P.V. and Sreekumar, K.P. (2010) Influence of Critical Plasma Spraying Parameter (CPSP) on Plasma Sprayed Alumina-Titania Composite Coatings. Ceramics International, 36, 141-149.
http://dx.doi.org/10.1016/j.ceramint.2009.07.012
[14]  Singh, V.P., Sil, A. and Jayaganthan, R.A. (2011) Study on Sliding and Erosive Wear Behaviour of Atmospheric Plasma Sprayed Conventional and Nanostructured Alumina Coatings. Materials and Design, 32, 584-591.
http://dx.doi.org/10.1016/j.matdes.2010.08.019
[15]  Sathish, S., Geetha, M., Aruna, S.T., Balaji, N., Rajam, K.S. and Asokamani, R. (2011) Sliding Wear Behaviour of Plasma Sprayed Nanocermic Coatings for Biomedical Applications. Wear, 271, 934-941.
http://dx.doi.org/10.1016/j.wear.2011.03.023
[16]  Sathish, S., Geetha, M., Aruna, S.T., Balaji, N., Rajam, K.S. and Asokamani, R. (2011) Studies on Plasma Sprayed Bi-Layered Ceramic Coating on Bio-Medical Ti-13Nb-13Zr Alloy. Ceramics International, 37, 1333-1339.
http://dx.doi.org/10.1016/j.ceramint.2010.12.012
[17]  Datta, S., Pratihar, D.K. and Bandyopadhyay, P.P. (2013) Modeling of Plasma Spray Coating Process Using Statistical Regression Analysis. The International Journal of Advanced Manufacturing Technology, 65, 967-980.
http://dx.doi.org/10.1007/s00170-012-4232-y
[18]  Palanivelu, R. and Kumar, A.R. (2014) Scratch and Wear Behaviour of Plasma Sprayed Nano Ceramics Bilayer Al2O3-13 wt%TiO2/Hydroxyapatite Coated on Medical Grade Titanium Substrates in SBF Environment. Applied Surface Science, 315, 372-379.
http://dx.doi.org/10.1016/j.apsusc.2014.07.167
[19]  Perumal, G., Geetha, M., Asokamani, R. and Alagumurthi, N. (2014) Wear Studies on Plasma Sprayed Al2O3-40 wt% 8YSZ composite Ceramic Coating on Ti-6Al-4V Alloy Used for Biomedical Applications. Wear, 311, 101-113.
http://dx.doi.org/10.1016/j.wear.2013.12.027
[20]  Mishra, N.K., Mishra, S.B. and Kumar, R. (2014) Oxidation Resistance of Low-Velocity Oxy Fuel-Sprayed Al2O3-13TiO2 Coating on nickel-Based Superalloys at 800℃. Surface and Coatings Technology, 260, 23-27.
http://dx.doi.org/10.1016/j.surfcoat.2014.07.089
[21]  Bolleddu, V., Racherla, V. and Bandyopadhyay, P.P. (2014) Microstructural and Tribological Characterization of Air Plasma Sprayed Nanostructured Alumina-Titania Coatings Deposited with Nitrogen and Argon as Primary Plasma Gases. Materials & Design, 59, 252-263.
http://dx.doi.org/10.1016/j.matdes.2014.02.040
[22]  Yang, Y., Wang, Y., Tian, W., Yan, D.-R., Zhang, J.X. and Wang, L. (2015) Influence of Composite Powders’ Microstructure on the Microstructure and Properties of Al2O3-TiO2 Coatings Fabricated by Plasma Spraying. Materials & Design, 65, 814-822.
http://dx.doi.org/10.1016/j.matdes.2014.09.078
[23]  Forghani, M., Ghazali, M.J., Muchtar, A., Daud, A.R., Yusoff, N.H.N. and Azhari, C.H. (2013) Effects of Plasma Spray Parameters on TiO2-Coated Mild Steel Using Design of Experiment (DoE) Approach. Ceramics International, 39, 3121-3127.
http://dx.doi.org/10.1016/j.ceramint.2012.09.092
[24]  Yusoff, N.H.N., Ghazali, M.J., Isa, M.C., Daud, A.R., Muchtar, A. and Forghani, S.M. (2012) Optimization of Plasma Spray Parameters on the Mechanical Properties of Agglomerated Al2O3-13%TiO2 Coated Mild Steel. Materials & Design, 39, 504-508.
http://dx.doi.org/10.1016/j.matdes.2012.03.019
[25]  Sure, J., Shankar, A.R. and Mudali, U.K. (2013) Surface Modification of Plasma Sprayed Al2O3-40 wt% TiO2 Coatings by Pulsed Nd:YAG Laser Melting. Optics & Laser Technology, 48, 366-374.
http://dx.doi.org/10.1016/j.optlastec.2012.09.025
[26]  Yilmaz, S., Ipek, M., Celebi, G.F. and Bindal, C. (2005) The Effect of Bond Coat on Mechanical Properties of Plasma-Sprayed Al2O3 and Al2O3-13 wt% TiO2 Coatings on AISI 316L Stainless Steel. Vacuum, 77, 315-321.
http://dx.doi.org/10.1016/j.vacuum.2004.11.004
[27]  Vargas, F., Ageorges, H., Fournier, P., Fauchais, P. and López, M.E. (2010) Mechanical and Tribological Performance of Al2O3-TiO2 Coatings Elaborated by Flame and Plasma Spraying. Surface and Coatings Technology, 205, 1132-1136.
http://dx.doi.org/10.1016/j.surfcoat.2010.07.061
[28]  Kang, J.J., Xu, B.-S., Wang, H.-D. and Wang, C.-B. (2014) Influence of Contact Stress on Rolling Contact Fatigue of Composite Ceramic Coatings Plasma Sprayed on a Steel Roller. Tribology International, 73, 47-56.
http://dx.doi.org/10.1016/j.triboint.2013.12.019
[29]  Chaitanya, M., Satapathy, A., Mishra, S.C., Ananthapadmanabhan, P.V. and Sreekumar, K.P. (2006) Neural Network Analysis for Deposition of Nickel-Aluminide Coatings on Steel by Plasma Spraying. 21st National Symposium of Plasma Science Society of India, MNIT, Jaipur, India.
[30]  Sahu, A., Das, R., Sen, S., Mishra, S.C., Satapathy, A., Ananthapadmanabhan, P.V. and Sreekumar, K.P. (2007) Al2O3-TiO2 Wear Resistant Coatings: A Neural Computation. International Conference on Advanced materials and Composites, CSIR, Trivandrum, India, 741-746.
[31]  Lin, H.L. (2013) Optimization of Inconel 718 Alloy Welds in an Activated GTA Welding via Taguchi Method, Gray Relational Analysis, and a Neural Network. The International Journal of Advanced Manufacturing Technology, 67, 939-950.
http://dx.doi.org/10.1007/s00170-012-4538-9
[32]  Song, R.G. (2003) Hydrogen Permeation Resistance of Plasma-Sprayed Al2O3 and Al2O3-13 wt.% TiO2 Ceramic Coatings on Austenitic Stainless Steel. Surface and Coatings Technology, 168, 191-194.
http://dx.doi.org/10.1016/S0257-8972(03)00002-1
[33]  Yin, Z., Tao, S., Zhou, X. and Ding, C. (2007) Tribological Properties of Plasma Sprayed Al/Al2O3 Composite Coatings. Wear, 263, 1430-1437.
http://dx.doi.org/10.1016/j.wear.2007.01.052
[34]  Datta, S., Pratihar, D.K. and Bandyopadhyay, P.P. (2012) Modeling of Input-Output Relationships for a Plasma Spray Coating Process Using Soft Computing Tools. Applied Soft Computing, 12, 3356-3368.
http://dx.doi.org/10.1016/j.asoc.2012.07.015
[35]  Manavizadeh, N., Rabbani, M. and Radmehr, F. (2015) A New Multi-Objective Approach in Order to Balancing and Sequencing U-Shaped Mixed Model Assembly Line Problem: A Proposed Heuristic Algorithm. The International Journal of Advanced Manufacturing Technology, 79, 415-425.
http://dx.doi.org/10.1007/s00170-015-6841-8
[36]  Zhang, Y.W., Zou, P., Li, B.Z. and Liang, S. (2015) Study on Optimized Principles of Process Parameters for Environmentally Friendly Machining Austenitic Stainless Steel with High Efficiency and Little Energy Consumption. The International Journal of Advanced Manufacturing Technology, 79, 89-99.
http://dx.doi.org/10.1007/s00170-014-6763-x
[37]  Xu, W.H., Lin, S.B., Fan, C.L. and Yang, C.L. (2015) Prediction and Optimization of Weld Bead Geometry in Oscillating Arc Narrow Gap All-Position GMA Welding. The International Journal of Advanced Manufacturing Technology, 79, 183-196.
http://dx.doi.org/10.1007/s00170-015-6818-7
[38]  Wang, J.T., Zhang, D.H., Wu, B.H., Luo, M. and Zhang, Y. (2015) Kinematic Analysis and Feedrate Optimization in Six-Axis NC Abrasive Belt Grinding of Blades. The International Journal of Advanced Manufacturing Technology, 79, 405-414.
http://dx.doi.org/10.1007/s00170-015-6824-9
[39]  Omidiji, B.V., Owolabi, H.A. and Khan, R.H. (2015) Application of Taguchi’s Approach for Obtaining Mechanical Properties and Microstructures of Evaporative Pattern Castings. The International Journal of Advanced Manufacturing Technology, 79, 461-468.
http://dx.doi.org/10.1007/s00170-015-6856-1
[40]  Arunachalam, A.P.S., Idapalapati, S. and Subbiah, S. (2015) Multi-Criteria Decision Making Techniques for Compliant Polishing Tool Selection. The International Journal of Advanced Manufacturing Technology, 79, 519-530.
http://dx.doi.org/10.1007/s00170-015-6822-y
[41]  Pérez-Rodríguez, R., Hernández-Aguirre, A. and Jöns, S. (2015) A Continuous Estimation of Distribution Algorithm for the Online Order-Batching Problem. The International Journal of Advanced Manufacturing Technology, 79, 569-588.
http://dx.doi.org/10.1007/s00170-015-6835-6
[42]  Maity, S.R. and Chakraborty, S. (2015) Tool Steel Material Selection Using PROMETHEE II Method. The International Journal of Advanced Manufacturing Technology, 78, 1537-1547.
http://dx.doi.org/10.1007/s00170-014-6760-0
[43]  Boopathi, S. and Sivakumar, K. (2013) Experimental Investigation and Parameter Optimization of Near-Dry Wire-Cut Electrical Discharge Machining Using Multi-Objective Evolutionary Algorithm. The International Journal of Advanced Manufacturing Technology, 67, 2639-2655.
http://dx.doi.org/10.1007/s00170-012-4680-4
[44]  Rao, R.V., Savsani, V.J. and Vakharia, D.P. (2011) Teaching-Learning-Based Optimization: A Novel Method for Constrained Mechanical Design Optimization Problems. Computer-Aided Design, 43, 303-315.
http://dx.doi.org/10.1016/j.cad.2010.12.015
[45]  Rao, R.V. (2015) Teaching Learning Based Optimization Algorithm and Its Engineering Applications. Springer International Publishing, Switzerland.
[46]  Pickard, J., Carretaro, J.A. and Bhavsar, V.C. (2016) On the Convergence and Origin Bias of the Teaching-Learning-Based-Optimization Algorithm. Applied Soft Computing, 46, 115-127.
http://dx.doi.org/10.1016/j.asoc.2016.04.029
[47]  Rao, R.V. and Patel, V. (2013) Comparative Performance of an Elitist Teaching-Learning-Based Optimization Algorithm for Solving Unconstrained Optimization Problems. International Journal of Industrial Engineering Computations, 4, 29-50.
http://dx.doi.org/10.5267/j.ijiec.2012.09.001
[48]  Rao, R.V. and Patel, V. (2012) An Elitist Teaching-Learning-Based Optimization Algorithm for Solving Complex Constrained Optimization Problems. International Journal of Industrial Engineering Computations, 3, 535-560.
http://dx.doi.org/10.5267/j.ijiec.2012.03.007
[49]  Crepinsek, M., Liu, S.-H. and Mernik, L. (2012) A Note on Teaching-Learning-Based Optimization Algorithm. Information Sciences, 212, 79-93.
http://dx.doi.org/10.1016/j.ins.2012.05.009
[50]  Waghmare, G. (2013) Comments on “a Note on Teaching-Learning-Based Optimization Algorithm”. Information Sciences, 29, 159-169.
http://dx.doi.org/10.1016/j.ins.2012.11.009
[51]  Rao, R.V. (2015) Review of Applications of TLBO Algorithm and a Tutorial for Beginners to Solve the Unconstrained and Constrained Optimization Problem. Decision Science Letters, 5, 1-30.
[52]  Crepinsek, M., Liu, S.-H., Mernik, L. and Mernik, M. (2014) Is a Comparison of Results Meaningful from the Inexact Replications of Computational Experiments? Soft Computing, 1-13.
[53]  Saaty, T.L. (2000) Fundamentals of the Analytic Hierarchy Process. RWS Publications, Pittsburgh.
[54]  Rao, R.V. (2016) Jaya: A Simple and New Optimization Algorithm for Solving Constrained and Unconstrained Optimization Problems. International Journal of Industrial Engineering Computations, 7, 19-34.

Full-Text

Contact Us

service@oalib.com

QQ:3279437679

WhatsApp +8615387084133