Inuences of atmospheric plasma spraying parameters on the abradable coating 410 wt.% LaPO-porosity value of YSZ using response surface methodology (RSM)

Due to the significant effect of porosity on the abradability behavior of ceramic abradable coatings and dependence of porosity value on the thermal spraying parameters, the aim of this research is to develop an empirical relationship between the atmospheric plasma process parameters and porosity value of YSZ-10wt.%LaPO4 abradable coating by surface response methodology. Full factorial design was used to investigate the effects of three varying principal parameters at two levels, namely, the current (400 and 800 A), the primary gas flow rate (25 and 40 lit/min) and the secondary gas flow rate (0 and 8 lit/min), on porosity of coating. Porosity was measured using optical and SEM images with software image analyzer (ImageJ). Results revealed that value of the porosity constantly decreases with increasing of current and secondary gas flow rate and with decreasing of primary gas flow rate. Furthermore, current and primary gas flow rate have highest and lowest impact on the porosity level, respectively.