Multi-output optimization of tribological characteristics control factors of thermally sprayed industrial ceramic coatings using hybrid Taguchi-grey relation analysis

Mohammed YUNUS; Mohammad S. ALSOUFI

doi:10.1007/s40544-016-0118-6

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Research Article | Open Access

Multi-output optimization of tribological characteristics control factors of thermally sprayed industrial ceramic coatings using hybrid Taguchi-grey relation analysis

Mohammed YUNUS(), Mohammad S. ALSOUFI

Mechanical Engineering Department, College of Engineering and Islamic Architecture, Umm Al-Qura University, Makkah 21514, Kingdom of Saudi Arabia

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Abstract

Lasma-sprayed thermal barrier coatings (TBCs) are gaining wide popularity and becoming more attractive for many industrial applications due to their high strength, thermal barrier/fatigue characteristics at elevated temperatures, resistance to chemical degradation, wear resistance, and environmental corrosion protection provided when coated on the surface of engineering components. To characterize the tribological properties of TBCs, a better understanding of their failure mechanisms and a thorough investigation of their performance are required. In this research, we used Taguchi-based grey relational analysis (GRA) to optimize the process parameters of various tribological characteristics of ceramic coatings applied via an atmospheric plasma spray process. Using Taguchi L16 factorial mixed-level experimental design, we also evaluated tribological characteristics such as wear loss and the coefficient of friction. Using GRA, we successfully performed a multiple output optimization and ranking of the control factors. Based on ANOVA results, we evaluated the significance of each process parameter and validated our findings in tests using the obtained optimum set of process parameters. Our study results will help to minimize wear loss and the coefficient of friction and to maximize TBC life.

Keywords

tribological characteristics wear loss coefficient of friction hybrid Taguchi-grey relational analysis analysis of variance (ANOVA)thermal barrier coatings (TBCs)

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Friction

Volume 4 Issue 3,
September 2016

Pages 208-216

DOI: 10.1007/s40544-016-0118-6

Cite this article:

YUNUS M, ALSOUFI MS. Multi-output optimization of tribological characteristics control factors of thermally sprayed industrial ceramic coatings using hybrid Taguchi-grey relation analysis. Friction, 2016, 4(3): 208-216. https://doi.org/10.1007/s40544-016-0118-6

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10.1007/s40544-016-0118-6.T001Table 1Control factors and their levels for tribological characteristics of TBC.

Process parameters	Notation	Unit	Levels of parameters
Process parameters	Notation	Unit	Level 1	Level 2	Level 3	Level 4
Applied pressure	P	MPa	0.05	0.15	0.25	0.3
Sliding distance	D	km	2	4	6	8
Sliding velocity	V	m/s	2.5	5	7.5	10
Type of coating	C	—	Alumina (A)	Alumina titania (AT)	Partial stabilized zirconia (PSZ)	Super-Z

10.1007/s40544-016-0118-6.T002Table 2Taguchi L16 orthogonal array for experimental layout.

Run No.	P	D	V	C	Run No.	P	D	V	C
1	1	1	1	1	9	3	1	3	4
2	1	2	2	2	10	3	2	4	3
3	1	3	3	3	11	3	3	1	2
4	1	4	4	4	12	3	4	2	1
5	2	1	2	3	13	4	1	4	2
6	2	2	1	4	14	4	2	3	1
7	2	3	4	1	15	4	3	2	4
8	2	4	3	2	16	4	4	1	3

10.1007/s40544-016-0118-6.T003Table 3Experimental results and data preprocessing of tribological characteristics of TBC coatings.

Run No.	TBC process parameters				Experimental results		Normalized data
Run No.	Applied pressure(MPa)	Sliding distance(km)	Sliding velocity(m/s)	Type of coating	Weight loss/wear (mg)	Coefficient of friction, µ	Weight loss/wear (mg)	Coefficient of friction, µ
Ideal sequence							1	1
1	0.05	2	2.5	A	0.17	0.075	1	0.576923
2	0.05	4	5	AT	0.59	0.082	0.97882	0.523077
3	0.05	6	7.5	PSZ	4.5	0.024	0.781644	0.969231
4	0.05	8	10	Super-Z	5.8	0.02	0.716087	1
5	0.15	2	5	PSZ	3.3	0.077	0.842158	0.561538
6	0.15	4	2.5	Super-Z	9	0.062	0.554715	0.676923
7	0.15	6	10	A	14	0.06	0.302572	0.692308
8	0.15	8	7.5	AT	9.1	0.078	0.549672	0.553846
9	0.25	2	7.5	Super-Z	9.7	0.065	0.519415	0.653846
10	0.25	4	10	PSZ	20	0.07	0	0.615385
11	0.25	6	2.5	AT	11	0.085	0.453858	0.5
12	0.25	8	5	A	15	0.055	0.252143	0.730769
13	0.3	2	10	AT	19	0.076	0.050429	0.569231
14	0.3	4	7.5	A	13.3	0.05	0.337872	0.769231
15	0.3	6	5	Super-Z	9	0.15	0.554715	0
16	0.3	8	2.5	PSZ	9	0.061	0.554715	0.684615

10.1007/s40544-016-0118-6.T004Table 4Deviation coefficients and grey relational coefficients of tribology characteristics of TBC coatings.

Run No.	Deviation coefficient		Grey relational coefficient
Run No.	Wear loss	Friction	Wear loss	Friction
Ideal sequence			1	1
1	0	0.423077	1	0.541667
2	0.02118003	0.476923	0.959361	0.511811
3	0.21835603	0.030769	0.696034	0.942029
4	0.28391326	0	0.637826	1
5	0.15784165	0.438462	0.760061	0.532787
6	0.44528492	0.323077	0.528941	0.607477
7	0.69742814	0.307692	0.417562	0.619048
8	0.45032779	0.446154	0.526134	0.528455
9	0.48058497	0.346154	0.5099	0.590909
10	1	0.384615	0.333333	0.565217
11	0.54614221	0.5	0.477946	0.5
12	0.74785678	0.269231	0.400687	0.65
13	0.94957136	0.430769	0.34493	0.53719
14	0.66212809	0.230769	0.430245	0.684211
15	0.44528492	1	0.528941	0.333333
16	0.44528492	0.315385	0.528941	0.613208

10.1007/s40544-016-0118-6.T005Table 5Grey relational grades and their order.

Run No.	Grey grade	Order	Run No.	Grey grade	Order
1	0.770833	3	9	0.550404	9
2	0.735586	4	10	0.449275	14
3	0.819031	1	11	0.488973	13
4	0.818913	2	12	0.525344	11
5	0.646424	5	13	0.44106	15
6	0.568209	7	14	0.557228	8
7	0.518305	12	15	0.431137	16
8	0.527295	10	16	0.571074	6

10.1007/s40544-016-0118-6.T006Table 6Response table for means of grey relational grade.

Process parameters	Grey relational grade				(Max – Min)	Rank
Process parameters	Level 1	Level 2	Level 3	Level 4	(Max – Min)	Rank
Applied pressure (MPa)	0.7861	0.5651	0.5035	0.5001	0.2860	1
Sliding distance (km)	0.6022	0.5776	0.5644	0.6107	0.0463	4
Sliding velocity (m/s)	0.5998	0.5846	0.6135	0.5569	0.0566	3
Type of coating	0.5929	0.5482	0.6215	0.5922	0.0732	2

Total mean grey relational grade = 0.5877

10.1007/s40544-016-0118-6.T007Table 7ANOVA results for grey relational grade.

Parameters	DF	SS	Adj MS	F	P	Contribution ratio (%)
Applied pressure (MPa)	3	0.218508	0.072836	15.59	0.025	85.33
Sliding distance (km)	3	0.005520	0.001840	0.39	0.768	2.16
Sliding velocity (m/s)	3	0.007063	0.002354	0.5	0.706	2.75
Type of coating		0.010962	0.003654	0.78	0.578	4.28
Error	3	0.014015	0.004672			5.4732
Total	15	0.256067				100.00

10.1007/s40544-016-0118-6.T008Table 8Results of TBC tribological performance using the initial and optimal process parameters.

	Initial process parameters	Optimal process parameters
	Initial process parameters	Prediction	Experiment
Level	P2-D2-V2-C2	P1-D4-V3-C3	P1-D4-V3-C3
Wear loss	9.3		4.85
Coefficient of friction	0.065		0.03
Grey relational grade	0.7556	0.8687	0.846