Modeling of plasma spray coating process using statistical regression analysis

This study aimed to correlate outputs of a plasma spray coating process with its input parameters. Central composite design of experiments had been followed to conduct the experiments on plasma spray coating process, in order to collect its input–output data. The effects of four input parameters, namely primary gas flow rate, stand-off distance, powder flow rate, and arc current on three outputs (responses), such as thickness, porosity, and microhardness of the coatings, had been studied using non-linear statistical regression analysis. Such an analysis yielded the response equations, and viability of these equations had been tested on a set of experimentally obtained cases. The above four process parameters were found to have varying influences on different responses. However, all the above three responses were found to be significantly dependent on primary gas flow rate.