Using response surface methodology with response transformation in optimizing plasma spraying coatings

The paper aims at proposing a method to develop a robust partially stabilized zirconia (PSZ) performance for the plasma spraying process with applications of surface response methodology and fractional factorial experiment. First, with the application of analysis of variance, significant factors are screened. Appropriately choosing control factors while constructing response functions helps to develop a robust process. Second, a nonlinear response surface function is designed to explore the space of the process. This smooths the progress of developing not only a proper relation between yielded and process variables, but also an optimal parameter setting that produces desirable response values. Experimental results show that a quadratic model with the proposed two-step design make it a simple, effective, and efficient way to a robust process. Model prediction is improved by additional data transformation. Optimization of PSZ performance in the plasma spraying process has been achieved.