Experimental analysis and optimization of plasma spray parameters on porosity and corrosion wear of Cr₃C₂/8YSZ composite coated austenitic stainless steel

Plasma spraying is a prospective method frequently employed because of its increased effectiveness in ceramic coatings. Optimizing process parameters is necessary to maximize the coating performance. This study employed response surface methodology (RSM) to investigate the impact of process variables, including current, powder feed rate, and standoff distance, on the porosity and corrosive wear loss of Cr 3 C 2 [Formula: see text][Formula: see text][Formula: see text]8YSZ composite coating. Experiments were done using the central composite design method, and quadratic regression models were created for the responses based on the completed trials. All parameters are observed to be most significant as the obtained p-value is under the threshold of 0.05 as per the analysis of variance (ANOVA) calculations. The optimal plasma spray process parameters were determined to be 500 A of current, a powder feed rate of 46[Formula: see text]gm/min, and a standoff distance of 3 inches for the expected lowest corrosive wear loss of 0.000025[Formula: see text]mm/year and a reduced area percentage porosity value of 0.93.