Response surface modeling and parameter optimization of detonation spraying with enhanced coating performance

Detonation spraying is a kind of thermal spray process, widely applied to produce dense, hard coatings on engineering surfaces with the least porosity and higher adhesive strength. This coating process is characterized by the significant parameters chosen, which are optimized to understand the relationship between the process parameters. For the experimental study, detonation sprayed alumina coatings on EN19 steel substrates were used. Applying Response Surface Methodology, the investigation data on the influence of the key process parameters of fuel ratio, standoff distance and nitrogen pressure on micro hardness, coating thickness and deposition rate were modeled for optimization. The optimized parameters were Fuel/ O2Ratio of 1:2.5, Standoff distance of 191mm and N2Pressure of 75kPa.