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This study optimized plasma-sprayed ceramic coatings using Taguchi methods and grey-based fuzzy theory. The approach significantly improved multiple coating properties, enhancing overall quality.

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Area of Science:

  • Materials Science
  • Surface Engineering
  • Manufacturing Processes

Background:

  • Plasma-sprayed ceramic coatings are crucial for various industrial applications.
  • Optimizing multiple performance characteristics simultaneously presents a significant challenge.
  • Existing methods often struggle to balance competing surface property requirements.

Purpose of the Study:

  • To enhance the multi-response quality of plasma-sprayed ceramic coatings.
  • To apply grey theory and fuzzy models based on Taguchi design experiments for optimization.
  • To critically evaluate the impact of control parameters on coating surface properties.

Main Methods:

  • Utilized an L18 orthogonal array experiment with eight control factors.
  • Applied grey-based fuzzy theory and Taguchi methods for multi-response optimization.
  • Conducted analysis of variance (ANOVA) and Scanning Electron Microscopy (SEM) for surface analysis.

Main Results:

  • Achieved significant reductions in surface roughness (15.96%), porosity (65.35%), hardness (34.60%), wear depth (34.04%), and coating thickness (32.01%).
  • Demonstrated an overall 48.94% improvement in multi-properties compared to initial settings.
  • Identified optimal process parameters for enhanced plasma-sprayed coating performance.

Conclusions:

  • Taguchi methods combined with grey-based fuzzy theory effectively optimize plasma spraying processes.
  • The study successfully enhanced the multi-response quality of ceramic coatings.
  • Achieved desired improvements in critical coating surface properties through optimized parameters.