Optimisation Method for Parameters of Energy-Efficient and High-Performance Plasma Spray Process

Plasma spray welding is widely used in surface engineering and remanufacturing.To improve the efficiency of energy utilisation during the spray welding process and the performance of repaired parts, plasma spray welding parameters are optimised from three aspects, namely the efficiency of energy utilisation, the Vickers hardness of the repaired layer, and the residual stress on the boundary of the heat-affected zone on the workpiece surface.Based on the central composite design method, experiments were conducted to analyse the relationship between specific energy, Vickers hardness, residual stress, and process parameters.The objective functions of the energy efficiency, the Vickers hardness, and the residual stress during plasma spray welding were established by using the response surface methodology.A multi-objective optimisation model has been established based on the improved energy efficiency and process performance.Finally, the relationship between the energy efficiency and the repair process performance was discussed.