Prediction of adhesive strength, deposition efficiecny and wear behaviour of plasma spray coating of low grade mineral on mild steel and copper Substrate by soft computing technique

Abstract

Currently emerging technologies contains some of the most prominent ongoing advances,
innovations and developments in a variety of engineering field to advance surface property by
using modern technology. Because for higher productivity and efficiency across the entire
spectrum of manufacturing and engineering industries has ensured that most modern day
components/ parts are subjected to day by day increasing harsh environments in routine
operations. All the Critical industrial components of the machines are, therefore, prone to more
rapid degradation as the parts fail to withstand the aggressive operating conditions and this has
been affecting the industry’s economy to a very high extent. The prime objectives are to develop
essential surface properties with an economical process. Today the investigation explores the
coating potential of industrial wastes. Fly-ash emerges as a major waste from thermal power
plants. It mainly comprises of oxides of iron, aluminium, titanium and silicon along with some
other minor constituents. Fly-ash premixed with illmenite and quartz which are minerals of low
cost available in plenty are excellent for providing protection against resistant to erosion and
abrasive wear.
In this wide research world Plasma spraying is gaining acceptance for development of quality
coatings of various materials on a wide range of substrates. Use of the industrial wastes of such
kind as coating material minimizes the plasma spray coating deposition cost, which posed to be
the major obstacle to the wide spread purpose due to high cost of the spray grade powders.
Fly-ash+quartz+illmenite (weight percentage ratio: 55:25:20) is deposited on copper and mild
steel substrates by atmospheric plasma spraying, at operating power levels ranging from
10 to 20kW and after that characterization of the coatings is carried out. The properties/ quality
of the coatings depend on the operating condition, process parameters and materials used. The
plasma spraying process is controlled by interdependent parameter, co-relations and individual
effect on coating characteristics. The size of the particles of raw material used for coating is
characterized using Malvern Instruments a Laser particle size analyzer. Coating interface
adhesion strength is calculated using a method of coating pull, confirming to ASTM C-633
standard. Deposition efficiency is a key factor that determines the techno economics of the
process, evaluated for the deposited coatings. Coating thickness of the polished cross section is
measured, using an optical microscope.