This paper discusses the effect of plasma spray parameters of deposited agglomerated nano Al2O3- 13%TiO2 powders on commercial marine-grade mild steels. Prior to the coating work, the nanopowders were subjected to a two-level factorial design of experiment to optimize the operational spray parame- ters, namely, the primary gas pressure, the carrier gas pressure, and the powder feed rate. These opera- tional spray parameters potentially affect the following responses of the coatings: microhardness, wear rate, and surface roughness. The significant effect on surface roughness is due to the interaction factor with the carrier gas pressure. However, by changing the carrier gas pressure and the powder feed rate, an insignificant effect on the microhardness and wear rate is noted. In general, agglomerated Al2O3- 13%TiO2 nanopowder-coated steels, with the lowest primary pressure of 40 psi, carrier gas pressure of 20 psi, and the highest powder feed rate of 3 rpm, are most preferred.
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