Optimization of powder metallurgy processing parameters of Al2O3/Cu composite through Taguchi method with Grey relational analysis

This article investigates the effect of powder metallurgy processing parameters on multi-responses: mass density and hardness of Al2O3/Cu composite based on Taguchi method coupled with Grey relational analysis. Based on Taguchi's L18 orthogonal array, the experimental trial runs were conducted with four controllable powder processing parameters: milling time, compaction pressure, sintering temperature and holding time. The Grey relational analysis (GRA) was performed to find the optimal powder processing condition with Grey relational grade (GRG) as a measure of performance index. Analysis of variance (ANOVA), 3D surface plots and contour plots were used to express the most influential parameter that affects mass density and hardness of Al2O3/Cu composite. Confirmation tests were conducted to make sure the validity of test results. The scanning electron microscope (SEM) images show the presence of Al2O3 particle in the composite. The Energy Dispersive X-Ray (EDX) spectrum indicates the presence of chemical elements: Cu, Al, O in the composite. The results show that the optimal powder metallurgy parameter combination is A2B3C3D1. The mean Grey relational coefficient (GRC) analysis shows that the mass density was more easily influenced by factors considered compare to hardness. The mean GRG result shows that the compaction pressure has the strongest correlation to responses. The result of 3D surface plots, contour plots and ANOVA indicate that the compaction pressure has most influential parameter that affect GRG. The % contribution of parameters shows that the % contribution of compaction pressure is significant (80.22%) compare to other main effects and interaction effects. The confirmation tests revealed that the performance characteristic of Al2O3/Cu composite was improved by GRA based Taguchi technique. The Monte Carlo simulated model summery show that based on Taguchi L18 Orthogonal Array design, one can easily find the reality of what will be happening in a process. Therefore, optimization of processes parameter could be simplified by using the Grey-based Taguchi method. © 2019 The Authors