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Mullite plasma spraying for in situ repair of cracks in mullite refractories: Simultaneous optimization of porosity and thickness by statistical design of experiments

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Schrijnemakers, A. [LCIS/GreenMat, Department of Chemistry, University of Liège, Liège, Belgium] Francq, Bernard G. [UCL] Cloots, R. [LCIS/GreenMat, Department of Chemistry, University of Liège, Liège, Belgium] Vertruyen, B. [LCIS/GreenMat, Department of Chemistry, University of Liège, Liège, Belgium] Boschini, F. [LCIS/GreenMat, Department of Chemistry, University of Liège, Liège, Belgium]

We report a laboratory-scale study about the suitability of the plasma spraying process for "in situ" repair of cracks in mullite refractories of industrial furnaces. The "design of experiments" approach is used to investigate how the coating porosity and thickness are influenced by six experimental parameters. Arc current, secondary gas (H 2) flow rate, and stand-off distance are the most significant parameters for both responses. Several interaction terms also affect significantly the thickness response. The validity of the model equations is discussed both from a statistical point of view and regarding the physical credibility of the main model terms. Additional experiments confirm that the measured properties lie into the prediction intervals provided by the model. Using a set of parameters optimized for minimal porosity and high thickness (relevant for the crack repair application), coatings with 6% porosity and 1070 μm thickness can be prepared reproducibly. © 2013 ASM International.

Document type Article de périodique (Journal article) – Article de recherche
Access type Accès restreint
Publication date 2013
Language Anglais
Journal information "Journal of Thermal Spray Technology" - Vol. 22, no. 7, p. 1133-1139 (2013)
Peer reviewed yes
Publisher Springer New York LLC
e-issn 1544-1016
issn 1059-9630
Publication status Publié
Affiliation UCL - SSH/LIDAM/ISBA - Institut de Statistique, Biostatistique et Sciences Actuarielles
Links
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Bibliographic reference Schrijnemakers, A. ; Francq, Bernard G. ; Cloots, R. ; Vertruyen, B. ; Boschini, F.. Mullite plasma spraying for in situ repair of cracks in mullite refractories: Simultaneous optimization of porosity and thickness by statistical design of experiments. In: Journal of Thermal Spray Technology, Vol. 22, no. 7, p. 1133-1139 (2013)
Permanent URL http://hdl.handle.net/2078.1/160739