| Résumé | NiCrAlY coatings were deposited using the Mettech Axial III™ plasma spray system. The microstructural features of the coatings, such as the porosity, crack, un-melted particle, and oxide content, were analyzed to investigate the effects of the spray process parameters on these features. Two Taguchi arrays were used to examine the effects of the spray process parameters such as powder size, ratio of (H2 + N2) gas flow over total gas flow, current, spray-gun nozzle size, and spray distance, on the microstructural features of the coatings. The results from statistical analysis are used to create regression equations to predict the microstructural features of the coatings. In the regression equations, a process index (PI) is used as a complex variable incorporating a number of process parameters. The results from an additional set of experiments are used to verify the validity of the regression equations. It has been demonstrated that the equations correlate well with the results from the subsequent set of experiments. It is concluded from this study that the PI can be used to categorize coating qualities with respect to the extent of crack, porosity, unmelted particle, and oxide content in the coating. These equations can also serve as an initial step in developing process parameters by means of the Mettech Axial III™ System. |
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