Modeling of input–output relationships for a plasma spray coating process using soft computing tools

To automate any manufacturing process, its input–output relationships are to be known in both forward and reverse directions. The present work aims to correlate input process parameters with various responses of a plasma spray coating process. Statistical regression analysis had been carried out previously for this process based on the data collected through central composite design of experiments to establish input–output relationships in forward direction. However, the said relationships could not be accurately determined in reverse direction using the obtained regression equations due to the presence of a non-square transformation matrix. Soft computing-based approaches had been developed to model the process in both forward as well as reverse directions. The performances of the developed approaches had been tested on different cases obtained through real experiments. A comparative study had been made of these developed approaches in terms of accuracy in predictions.

Graphical abstractFigure optionsDownload full-size imageDownload as PowerPoint slideHighlights► Modeling of plasma spray coating process. ► Forward and reverse mappings. ► Neural networks. ► Genetic algorithms. ► Particle swarm optimization.