Process modeling and mapping for a plasma spray coating process

Plasma spray is critical in thermal barrier coating (TBC) for aero-engines, land-based turbines and fuel cells. Many process variables and in-situ variables can affect the final coating properties during the plasma generation, plasma particle interaction, and coating formation stages. Due to the process complexity and lack of sensing methods, the repeatability and reproducibility of the process remains a challenge. In this paper, a fractional factorial design is conducted, with in-situ process variables, in-flight particle conditions and coating properties measured, to study the plasma spray process. A regression model is used to map the design of experiments (DOE) factors, in-situ process variables and in-flight particle conditions with coating properties. Significant factors, in-situ process variables and inflight particle conditions are identified.