Statistical Analysis and Optimization of Atmospheric Plasma Spraying Parameters to Attain Maximum Corrosion Resistance in Alumina Coatings on AZ31B Magnesium Alloy

In this study, an attempt has been made to establish an empirical relationship is developed to predict corrosion rate of the atmospheric plasma sprayed alumina coatings on AZ31B magnesium alloy by incorporating process parameters such as power, stand-off distance and powder feedrate. Statistical tools such as design of experiments, analysis of variance, and regression analysis are used to develop the relationships. The developed empirical relationship can be effectively used to predict the corrosion rate of plasma sprayed alumina coated AZ31B magnesium alloy at the 95% confidence level. Sensitivity analysis was carried out and compared with the relative impact of three process parameters on corrosion rate to verify the measurement errors on the values of the uncertainty in estimated parameters. The results indicate that the input power has the greatest influence on corrosion rate, followed by stand-off distance and powder feedrate.