Yield improvement for lost mould rapid infiltration forming process by a multistage fractional factorial split plot...

Area of Science:

• Materials Science
• Chemical Engineering
• Industrial Engineering

Background:

• Statistical design of experiments (DOE) is crucial for process optimization.
• The principle of randomization in DOE can be time-consuming and costly for complex, multi-stage processes.
• Existing methods may not be suitable for intricate manufacturing like zirconia ceramic fabrication.

Purpose of the Study:

• To propose and evaluate a multistage fraction factorial split plot design for improving green yield in zirconia ceramic production.
• To address the practical limitations of strict randomization in complex manufacturing processes.
• To identify key factors influencing yield in the lost mould rapid infiltration process.

Main Methods:

• Implementation of a multistage fraction factorial split plot design.
• Application to a lost mould rapid infiltration process for zirconia ceramic fabrication.
• Relaxation of the randomization principle to allow grouped experimental runs.

Main Results:

• The study identified specific immersion chemicals and mould coatings that significantly improve process yield.
• The multistage fraction factorial split plot design demonstrated feasibility for complex processes.
• Results suggest that utilizing a mould infiltration machine enhances process reproducibility.

Conclusions:

• The proposed design offers a practical alternative to strict randomization in complex industrial settings.
• Immersion chemical and mould coating are critical variables for enhancing green yield.
• Automated mould infiltration is recommended for improved process consistency and yield in zirconia ceramic manufacturing.