Adaptive Control of the Atmospheric Plasma Spray Process for Functionally Graded Thermal Barrier Coatings

Table 4

Comparison of desired outputs for the NiCrAlY and the ZrO₂ powders with those found from LAVA-P using the process parameters obtained as solutions of equations (20) and (21).

Desired outputs			Process parameters from equation (20) and (21)					Measured outputs from LAVA-P			Error between desired and measured outputs
(m/s)	(K)	(cm)	(slm)	(slm)	(A)	(cm/s)	(cm)	(m/s)	(K)	(cm)	(%)	(%)	(%)
Single injection system using the NiCrAlY powder,
70	2400	−1.0	43.06	4.81	479.68	855.0	1.21	69.1	2412	−1.02	1.3	−0.5	−2.0
60	2500	−1.1	34.44	5.45	453.99	794.3	1.22	62.1	2525	−1.05	−3.5	−1.0	4.5
80	2100	−1.2	56.37	5.70	393.93	1116.0	0.76	80.1	2096	−1.20	−0.1	0.2	0.0
85	2200	−1.1	55.00	4.97	454.71	1101.6	0.66	86.6	2214	−1.12	−1.9	−0.6	−1.8
75	2400	−1.0	44.69	4.51	482.48	902.8	0.99	74.9	2427	−1.01	0.1	−1.1	−1.0
65	2300	−1.3	44.06	13.80	399.60	992.0	1.20	64.2	2349	−1.30	1.2	−0.5	0.0
Single injection system using ZrO2 powder,
85	2600	−1.0	40.77	6.86	393.00	1061.0	1.22	86.3	2604	−1.00	−1.5	−0.2	0.0
90	2700	−0.9	39.34	11.20	389.25	980.6	1.15	91.5	2723	−0.88	−1.7	−0.9	2.2
95	2800	−0.8	39.16	6.18	463.54	941.6	1.11	96.0	2810	−0.78	−1.1	−0.4	2.5
100	2750	−1.1	44.03	8.82	527.96	1289.5	1.07	98.6	2733	−1.12	1.4	0.6	−1.8
105	2500	−1.0	50.84	6.99	383.62	1206.7	0.79	104.5	2505	−1.00	0.5	−0.2	0.0
110	2650	−1.2	49.75	10.78	423.30	1375.4	0.62	108.7	2618	−1.15	1.2	1.2	4.2