Optimization of High-Velocity Oxygen Fuel Spray Process Parameters to Achieve Maximum Thickness and Minimum Porosity in Vanadium Carbide Coating

In this research investigation, the optimization of the high-velocity oxygen fuel spray process parameters for achieving maximum coating thickness and minimum porosity percentage in VC coatings has been systematically explored. The study delved into the interplay of critical parameters including oxygen flow rate, LPG flow rate, and air flow rate, employing a Face Centered response surface methodology approach. Through a comprehensive analysis of interactive effects, response surface plots, and validation processes, this study uncovers profound insights that challenge conventional paradigms of coating optimization. Validation of the optimization parameters through experimental verification reaffirms the efficacy of the proposed model. The alignment between predicted and experimental results underscores the reliability of the optimization model in guiding parameter selections. Minor deviations observed further illuminate the delicate balance between theoretical precision and practical execution. The implications of this research extend to industries reliant on coatings, such as aerospace and manufacturing. The insights gained provide a roadmap for achieving not only desirable coating characteristics but also enhanced process understanding.