Better quality control: Stochastic approaches to optimize properties and performance of plasma-sprayed coatings

Journal of Thermal Spray Technology

Volumn 19, Issue 4, 2010, Pages 765-778

  Heimann, Robert B ^a  

^a Applied Mineralogy and Materials Science   (Germany)

Author keywords

Artificial neuronal networks; D optimal designs; Fuzzy logic control; Statistical design of experiments; Taguchi designs

Indexed keywords

ARTIFICIAL NEURONAL NETWORK; D-OPTIMAL DESIGNS; FUZZY LOGIC CONTROL; STATISTICAL DESIGN OF EXPERIMENTS; TAGUCHI DESIGN;

DESIGN OF EXPERIMENTS; FUZZY LOGIC; FUZZY SYSTEMS; NEURAL NETWORKS; OPTIMAL SYSTEMS; OPTIMIZATION; PLASMA SPRAYING; PROTECTIVE COATINGS; QUALITY CONTROL; SURFACE TESTING;

SPRAYED COATINGS;

EID: 78650843927     PISSN: 10599630     EISSN: None     Source Type: Journal    
DOI: 10.1007/s11666-009-9385-3     Document Type: Conference Paper

References (94)

1. S. Bisgaard, Optimizing Thermal Spray Processes-Going Beyond Taguchi Methods, Proc. 3rd NTSC, Long Beach, CA, May 20-25, 1990, p 661-668
2. R.B. Heimann, Plasma Spray Coating: Principles and Applications, 2nd ed., Wiley-VCH, Weinheim, 2008
3. C. Pierlot, L. Pawlowski, M. Bigan, and P. Chagnon, Design of Experiments in Thermal Spraying, Surf. Coat. Technol., 2008, 202, p 4483-4490
4. G. Pouskouleli and T.A. Wheat, Total Quality Management (TQM): Recipe for Survival, Transactions 17th CUICAC Workshop 'Ceramic Coatings-A Solution Towards Reducing Wear and Corrosion, R.B. Heimann, Ed., 2 Oct, Laval University, 1991
5. R.L. Plackett and J.P. Burman, The Design of Optimum Multifactorial Experiments, Biometrika, 1946, 33(4), p 305-325
6. A. Arcondéguy, G. Gasgnier, G. Montavon, B. Pateyron, A. Denoirjean, A. Grimaud, and C. Huguet, Effects of Spraying Parameters onto Flame-Sprayed Glaze Coating Structures, Surf Coat. Technol., 2008, 202(18), p 4444-4448
7. F. Yates, "The Design, and Analysis of Factorial Experiments," Techn. Comm. 35, Imperial Bureau Soil Sci.., Harpenden, UK, 1937
8. J.S. Hunter, The Inverse Yates Algorithm, Technometrics, 1966, 8, p 177-183
9. U.V. Diccar, "Plasma Spray Coatings for Polymer Composites," Master Thesis, Wichita State University, December 2006
10. E. Perez,"Development of APS MCrAIY Dense Bond Coats," Report, University of Central Florida, 2006. www.clemson.edu/scies/UTSR/FellowPerezSUM6- 2006.pdf
11. k-p Fractional Factorial Designs, Technometrics, 1961 3(3), p 311-331, 449-458
12. M. Eme,"Optimierung der Dichte, Dicke und Oberfiächenrauheit APS-gespritzter Chrom- oxid-Korrosionsschutzschichten," Unpublished 4th Year Thesis, Technische Universität Bergakademie Freiberg, 2004 (http://www.wissen24.de/vorschau/25257.html)
13. B.D. Sartwell, K.O. Legg, J. Schell, J. Sauer, P. Natishan, D. Dull, J. Falkowski, P. Bretz, J. Devereaux, C. Edwards, and D. Parker, "Validation of HVOF WC/Co Thermal Spray Coatings as a Replacement for Hard Chrome Plating on Aircraft Landing Gear," Naval Research Lab., Report No. NRL/MR/6170-048762, 2004, 280 pp
14. G. Taguchi and S. Konishi, Taguchi Methods: Orthogonal Arrays and Linear Graphs, ASI Press, Dearborn, MI, 1987
15. D.C. Montgomery, Design and Analysis of Experiments, Wiley, New York, 1991
16. P. Saravanan, V. Selvarajan, M.P. Srivastava, S.V. Joshi, and G. Sundararajan, Influence of Spraying Variables on Structure and Properties of Plasma Sprayed Alumina Coatings, Brit. Ceram. Trans, 2000, 99(6), p 241-247
17. P. Saravanan, V. Selvarajan, D. Srinivasa Rao, S.V. Joshi, and G. Sundararajan, Application of Taguchi Method to the Optimization of Detonation Spraying Process, Mater. Manufact. Process., 2000, 15(1), p 139-153
18. P. Saravanan, V. Selvarajan, M.P. Srivastava, D.S. Rao, S.V. Joshi, and G. Sundararajan, Study of Plasma- and Detonation Gun-Sprayed Alumina Coatings Using Taguchi Experimental Design, J. Thermal Spray Technol., 2000, 9(4), p 505-512
19. P. Saravanan, V. Selvarajan, S.V. Joshi, and G. Sundararajan, Experimental Design and Performance Analysis of Alumina Coatings Deposited by a Detonation. Spray Process, J. Phys. D Appl. Phys., 2001, 34, p 131-140
20. A. Kucuk, C.C.Berndt, U. Senturk, and R.S. Lima, Characterization of Mechanical Properties of TBCs via a Taguchi Experimental Design, Proc. 1st ITSC, Thermal Spray Surface Engineering via Applied Research, Montreal, QC, Canada, May 9-11, 2000, p 1211-1217
21. M. Cell, L. Xie, X. Ma, E.H. Jordan, and N.P. Padhure, Highly Durable Thermal Barrier Coatings Made by the Solution Precursor Plasma Spray Process, Surf. Coat. Technol., 2004, 177-178, p 97-102
22. J. Cizek, K.A. Khor, and Z. Prochazka, Influence of Spraying Conditions on Thermal and Velocity Properties of Plasma Sprayed Hydroxyapatite, Mater. Sci. Eng. C, 2007, 27(2), p 340-344
23. H.K. Kim, J.W. Jang, and C.H. Lee, Surface Modification of Implant Materials and its Effect on Attachment and Proliferation of Bone Cells, J. Mater. Sci. Mater. Med., 2004, 15(7), p 825-830
24. G. Gibbons and R. Hansell, Down-Selection and Optimization of Thermal-Sprayed Coatings for Aluminum Mould Tool Protection and Upgrade, J. Thermal Spray Technol., 2006, 15(3), p 340-347
25. F. Tarasi, M. Medraj, A. Dolatabadi, J. Oberste-Berghaus, and C Moreau, Effective Parameters in Axial Injection Suspension Plasma Spray Process of Alumina-Zirconia Ceramics, J. Thermal Spray Technol., 2008, 17(5-6), p 685-691
26. R.B. Heimann, D. Lamy, and T. Sopkow, Optimization of Vacuum Plasma Arc Spray Parameters of 88WC12Co Alloy Coatings Using a Statistical Multifactorial Design Matrix, J. Can. Ceram. Soc., 1990, 59(3), p 49
27. J. Grum and Z. Bergant, The Optimisation of Powder FlameSpraying Parameters Using a Taguchi Method, Int. J. Microstruct. Mater. Prop., 2008, 3(4-5), p 682-700
28. G. Bertrand, P. Bertrand, P. Roy, C. Rio, and R. Mevrel, Low Conductivity Plasma Sprayed Thermal Barrier Coating Using Hollow PSZ Spheres: Correlation Between Thermophysical Properties and Microstructure, Surf. Coat. Technol., 2008, 202(10), p 1994-2001
29. G.E.P. Box and D.W. Behnken, Some New Three Level Designs for the Study of Quantitative Variables, Technometrics, 1960, 2, p 455-475
30. F. Cipri, C. Bartuli, T. Valente, and F. Casadei, Electromagnetic and Mechanical Properties of Silica-Aluminosilicates Plasma Sprayed Composite Coatings, J. Thermal Spray Technol., 2007, 16(5-6), p 831-838
31. B.T. Lin, M.D. Jean, and J.H. Chou, Using Response Surface Methodology for Optimizing Deposited Partially Stabilized Zirconia in Plasma Spraying, Appl. Surf. Sci, 2007, 253(6), p 3254-3262
32. A. Schuppert and A. Ohrenberg, "Method and Computer for Experimental Design," EP1499930, 2005
33. G.E.P. Box and K.B. Wilson, On the Experimental Attainment of Optimum Conditions, J. Roy. Statist. Soc, 1951, 13, p 1-45
34. J. Bohm, M. Böhm, and R.B. Heimann, Voronoi Polyhedra: A Useful Tool to Determine the Symmetry and Bravais Class of Crystal Lattices, Cryst. Res. Technol., 1996, 31(8), p 1069-1075
35. 3-Schichten," Unpublished 4th Year Thesis, Technische Universität Bergakademie Freiberg, 2000
36. G. Reisel and R.B. Heimann, Correlation Between Roughness of Plasma-Sprayed Chromium Oxide Coatings and Powder Grain Size Distribution: A Fractal Approach, Surf. Coat. Technol., 2004, 183, p 215-221
37. Y. Wang and T.W. Coyle, Optimization of Solution Precursor Plasma Spray Process by Statistical Design of Experiment, J. Thermal Spray Technol., 2008, 17(5-6), p 692-699
38. H.O. Hartley, Smallest Composite Designs for Quadratic Response Surfaces, Biometrics, 1959, 15(4), p 611-624
39. A. Yudee, A. Sopadang, S. Wirojanupatump, and S. Jiansirisomboon, Aluminium-12wt% Silicon Coating Prepared by Thermal Spraying Technique: Part 1. Optimization of Spray Condition Based on a Design of Experiments, Songklanakarin J. Sci. Technol., 2006, 28(2), p 431-439
40. B.T. Neyer, A D-Optimality-Based Sensitivity Test, Technometrics, 1994, 36(1), p 61-70
41. C Pumplün, S. Rüping, K. Morik, and C Weihs, "D-Optimal Plans in Observational Studies," Report SFB 475 (Reduction of Complexity in Multivariate Data Structures), University Dortmund, Germany, 2005
42. M. Moldovan, C.M. Weyant, D.L. Johnson, and K.T. Faber, Tantalum Oxide Coatings as Candidate Environmental Barriers, J. Thermal. Spray Technol., 2004, 13(1), p 51-56
43. H.S. Haller, Experimental Design Optimizer (Software Manual), Harold S. Haller & Co, Cleveland, OH, 1999
44. F. Azarmi, T.W. Coyle, and J. Mostaghimi, Optimization of Atmospheric Plasma Spray Process Parameters Using a Design of Experiment for Alloy 625 Coatings, J. Thermal. Spray Technol., 2008, 17(1), p 144-155
45. J.F. Li, H. Liao, B. Normand, C. Codier, G. Maurin, J. Foct, and C. Coddet, Uniform Design Method for Optimization of Process Parameters of Plasma-Sprayed TiN Coatings, Surf. Coat. Technol., 2003, 176(1), p 1-13
46. K.T. Fang and Y. Wang, Number-Theoretic Methods in Statistics, Chapman and Hall, London, 1994
47. J.F. Li, H.L. Liao, C.X. Ding, and C. Coddet, Optimizing the Plasma Spray Process Parameters of Yttria Stabilized Zirconia Coatings Using a Uniform Design of Experiments, J. Mater. Proc. Technol., 2005, 160(1), p 34-42
48. J.R. Mawdsley, Y.J. Su, K.T. Faber, and T.F. Bernecki, Optimization of Small-Particle Plasma-Sprayed Alumina Coatings Using Designed Experiments, Mater. Sci. Eng. A, 2001, 308, p 189-199
49. S. Sampath, X. Jiang, A. Kulkarni, J. Matejicek, D.L. Gilmore, and R.A. Neiser, Development of Process Maps for Plasma Spray: Case Study for Molybdenum, Mater. Sci. Eng. A, 2003, 348, p 54-66
50. A. Vaidya, T. Streibl, L. Li, S. Sampath, O. Kovarik, and R. Greenlaw, An Integrated Study of Thermal Spray ProcessStructure-Property Correlations: A Case Study for Plasma Sprayed Molybdenum Coatings, Mater. Sci. Eng. A, 2005, 403(1-2), p 191-204
51. X. Jiang, J. Matejicek, A. Kulkarni, H. Herman, S. Sampath, D. Gilmore, and R. Neiser, "Process Maps for Plasma Spray Part II: Deposition and Properties," Report SAND2000-0802c, 2000, p 1-7
52. E. Turunen, T. Varis, T.E. Gustavson, J. Keskinen, T. Fäit, and S.P. Hannula, Parameter Optimization of HVOF Sprayed Nanostructured Alumina and Alumina-Nickel Composite Coatings, Surf. Coat. Technol., 2006, 200(16-17), p 4987-4994
53. W. Zhang and S. Sampath, A Universal Method for Representation of In-Flight Particle Characteristics in Thermal Spray Processes, J. Thermal Spray Technol., 2009, 18(1), p 23-24
54. A. Vaidya, V. Srinivasan, T. Streibl, M. Friis, W. Chi, and S. Sampath, Process Maps for Plasma Spraying of Yttria-Stabilized Zirconia: An Integrated Approach to Design, Optimization and Reliability, Mater. Sci. Eng. A, 2008, 497(1-2), p 239-253
55. J.C. Fang, H.P. Zeng, W.J. Wu, Z.Y. Zhao, and L. Wang, Prediction of In-Flight Particle Behaviors in Plasma Spraying, J. Achiev. Mater. Manufact. Eng., 2006, 18(1-2), p 283-286
56. H.B. Xiong, L.L. Zheng, and T. Streibl, A Critical Assessment of Particle Temperature Distribution During Plasma Spraying: Numerical Studies for YSZ, Plasma Chem., Plasma Proc., 2006, 26(1), p 53-72
57. B. Liu, T. Zhang, and D.T. Gawne, Computational Analysis of the Influence of Process Parameters on the Flow Field of a Plasma Jet, Surf. Coat. Technol., 2000, 132(2-3), p 202-216
58. I. Ahmed and T.L. Bergman, Optimization of Plasma Spray Processing Parameters for Deposition on Nanostructured Powders for Coating Formation, J. Fluid Eng., 2006, 128(2), p 394-401
59. C. Le Bot and E. Arquis, Numerical Study of the Solidification of Successive Thick Metal Layers, Int. J. Thermal Sci., 2009, 48(2), p 412-420
60. S. Hossainpour and A.R. Binesh, A CFD Study of Sensitive Parameter Effects on the Combustion in a High Velocity Oxygen Fuel Thermal Spray Gun, Proc. World Acad. Sci. Eng. Technol., 2008, 31, p 213-220
61. R. Cesaretti, High Throughput Screening of Coatings, Adhesive, Sealants and Elastomer (CASE) Formulations, Symyx Global Symp., Philadelphia, May 12-14, 2009, p 1
62. P, Seyffarth, A. Scharff, F.W. Bach, L.A. Josefiak, B. Bouaifi, and T. Schlennstedt, SprayWare-Beratungssystem für den Oberflächenschutz durch thermisches Spritzen, Schweissen und Schneiden, 2002, 54, p 192-199
63. F.I. Trifa, G. Montavon, and C. Coddet, Model-Based Expert System for Design and Simulation, of APS Coatings, J. Thermal Spray Technol., 2007, 16(1), p 128-139
64. S. Guessasma, G. Montavon, P. Gougeon, and C. Coddet, Designing Expert Systems Using Neural Computation in View of the Control of Plasma Spray Processes, Mater. Design, 2003, 24(7), p 497-502
65. Y. Siradeghyan, A. Zakarian, and P. Mohanty, Entropy-Based Associative Classification Algorithm for Mining Manufacturing Data, Int. J. Comput. Integr. Manufact., 2008, 21(7), p 825-838
66. C. Coddet, On the Use of Auxiliary Systems During Thermal Spraying, Surf. Coat. Technol., 2006, 201(5), p 1969-1974
67. D.D. Frey, F. Engelhardt, and E.M. Greitzer, A Role for "OneFactor-at-a-Time" Experimentation in Parameter Design, Res. Eng. Design, 2003, 14, p 65-74
68. X. Li, N. Sudarsanam, and D.D. Frey, Regularities in Data from Factorial Experiments, Complexity, 2006, 11(5), p 32-45
69. S. Guessasma, G. Montavon, and C. Coddet, Modeling of the APS Plasma Spray Process Using Artificial Neural Networks: Basis, Requirements and an Example, Comput. Mater. Sci., 2004, 29(3), p 315-333
70. M.M. Nelson, and W.T, Illingworth, A Practical Guide to Neural Nets, 3rd ed., Addison-Wesley, Reading, MA, 1991
71. J.B. Tenenbaum and W.T. Freeman, Separating Style and Content, Proc Advanc Neural Process Information Systems, M.C. Mozer, M.I. Jordan, and T. Petsche, Ed., Vol. 9, Part IV, The MIT Press, Cambridge, MA, USA, 1997, p 662-668
72. S. Guessasma and C. Coddet, Neural Computation Applied to APS Spray Process: Porosity Analysis, Surf. Coat. Technol., 2005, 197, p 85-92
73. W. McCulloch and W. Pitts, A Logical Calculus of Ideas Immanent in Nervous Activity, Bull. Math. Biophys., 1943, 7, p 115-133
74. L. Wang, J.C. Fang, Z.Y. Zhao, and H.P. Zeng, Application of Backward Propagation Network for Forecasting Hardness and Porosity of Coatings by Plasma. Spraying, Surf. Coat. Technol., 2007, 201(9-11), p 5085-5089
75. D. Patterson, Artificial Neural Networks, Prentice Hall, Singapore, 1996
76. S. Guessasma, G. Montavon, P. Gougeon, and C. Coddet, On the Neural Network Concept to Describe the Thermal Spray Deposition Process: Correlation Between In-Flight Particles Characteristics and Processing Parameters, Proc. ITSC 2002, E. Lugscheider and P.A. Kammer, Ed., DVS-Verlag, Düsseldorf, Germany, 2002, p 453-458
77. 2 (13% by Weight) Ceramic Coating Structure, J. Phys. IV France, 2004, 120, p 363-370
78. S. Guessasma, Z. Salhi, G. Montavon, P. Gougeon, and C. Coddet, Artificial Intelligence Implementation in the APS Process Diagnostics, Mater. Sci. Eng. B, 2004, 110(3), p 285-295
79. S. Guessasma, M. Bounazet, and P. Nardin, Neural Computation Analysis of Alumina-Titania Wear Resistance Coating, Int. J. Refract. Met. Hard Mater., 2006, 24(3), p 240-246
80. A.F. Kanta, G. Montavon, M.P. Planche, and C. Coddet, Artificial Intelligence Computation to Establish Relationships Between APS Process Parameters and Alumina-Titania Coating Properties, Plasma Chem. Plasma Proc., 2008, 28, p 249-262
81. M.D. Jean, B.T. Lin, and J.H. Chou, Application of an Artificial Neural Network for Simulating Robust Plasma-Sprayed Zirconia Coatings, J. Am. Ceram. Soc., 2008, 91(5), p 1539-1547
82. G. Zhang, S. Guessasma, H. Liao, C. Coddet, and J.M. Bordes, Investigation of Friction and Wear Behaviour of SiC-Filled PEEK Coating Using Artificial Neural Networks, Surf. Coat. Technol., 2006, 200(8), p 2610-2617
83. K. Bobzin, F. Ernst, J. Zwick, K. Richardt, R. Schmitt, and J. Dören, Increase of Process Robustness Through Offline Process Control and Noise Factor Influence Reduction, Proc. 2007 Intern. Thermal Spray Conf. (ISTC), Beijing, China, May 14-16, 2007, p 855-859
84. J. Dören, "Quality Management and Neural Networks: An Approach for Predictional Control of Thermal Spray Processes," Ph.D. Dissertation, Faculty of Mechanical Engineering, RWTH Aachen, Germany, 2007. URL: http://darwin.bth.rwth-aachen.de/opus3/volltexte/2007/1986
85. S. Guessasma, G. Montavon, and C. Coddet, Neural Networks, Design of Experiments and Other Optimization Methodologies to Quantify Parameter Dependence of Atmospheric Plasma Spraying, Thermal Spray 2003: Advancing The Science & Applying the Technology, C Moreau and B. Marple, Ed., Orlando, FL, May 5-8, 2003, p 939-948
86. A.F. Kanta, G. Montavon, M. Vardelle, M.P. Planche, C.C. Berndt, and C. Coddet, Artificial Neural Networks vs. Fuzzy Logic: Simple Tools to Predict and Control Complex ProcessesApplication to Plasma Spray Processes, J. Thermal Spray Technol., 2008, 17(3), p 365-376
87. M.D. Jean, B.T. Lin, and J.H. Chou, Design of a Fuzzy Logic Approach for Optimization Reinforced Zirconia Depositions Using Plasma Sprayings, Surf. Coat. Technol., 2006, 201(6), p 3129-3138
88. A.F. Kanta, G. Montavon, M.P. Planche, and C. Coddet, Prospect for Plasma Spray Processes On-Line Control Via Artificial Intelligence (Neural Networks and Fuzzy Logic), Thermal Spray 2006: Science, Innovation, and Application, Proc. 2006 ITSC, Seattle, WA, May 15-18, 2006, p 1027-1033
89. A.F. Kanta, G. Montavon, M.P. Planche, and C. Coddet, Fuzzy Logic Analysis of Alumina-Titania Deposition Yield During APS Process, J. Thermal Spray Technol., 2007, 16, p 913-918
90. A.F. Kanta, G. Montavon, M.P. Planche, and C. Coddet, InFlight Particle Characteristics Control by Implementing a Fuzzy Logic Controller, Surf. Coat. Technol., 2008, 202, p 4479-4482
91. L.A. Zadeh, Fuzzy Sets, Inform. Control, 1965, 8(3), p 338-353
92. H.J. Zimmermann, Fuzzy Set Theory, 2nd ed., Kluwer, Boston, 1991
93. T.J. Ross, Fuzzy Logic with Engineering Applications, Wiley, Chichester, 2004
94. E.H. Mamdani and S. Assilian, An Experiment in Linguistic Synthesis with a Fuzzy Logic Controller, IEEE Trans. Comput., 1975, 26(12), p 1182-1191