The foremost objectives are to develop required surface properties with economical process. Fly-ash premixed with quartz and illmenite which are low cost minerals available in plenty are excellent candidates for providing protection against abrasive wear and resistant to erosion. Plasma spraying is gaining acceptance for development of quality coatings of various materials on a wide range of substrates. Utilization of such kind of industrial waste as coating material minimizes the cost of plasma spray coating deposition, which posed to be the major hindrance to its wide spread application due to high cost of the spray grade powders. Fly-ash+quartz+illmenite having weight percentage ratio: 60:20:20 is deposited on mild steel and copper substrates by atmospheric plasma spraying. The properties of the coatings depend on the materials used, operating condition and the process parameters. The plasma spraying process is controlled by the parameter interdependencies, co-relations and individual effect on coating characteristics. Coating interface adhesion, Deposition efficiency, tribological, Coating porosity, Coating thickness are studied. By XRD analysis phase changes/transformation studied. The coating quality and behavior depends on Coating surface & interface morphology are studied with SEM. Wear properties of these coatings are studied by Air Jet Erosion Test Rig. In order to optimize the surface property for different application, one of the challenges is to recognize parameter interdependencies; correlations and their individual effects on process so that the coating can be useful for a specific application. This challenge can be analysed/predicted by Artificial Inteligence Methods. Statistical analysis of the experimental results using Artficial Neural Network and Taguchi experimental design is been made. Spraying parameters such as impact angle, size of the erodent, standoff distance and impact velocity are identified as the significant factors affecting the coating tribological property. This work establishes that fly-ash+quartz+illmenite composite mixture can be used as a potential coating material suitable for depositing plasma spray coating.
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