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<p>Cold spray (CS) parameter optimization is necessary to minimize corrosion and enhance the protective properties of composite coatings on lightweight alloys. In the present work, an evolutionary genetic algorithm (GA) was used to identify the optimum combination of CS parameters and further guarantee good corrosion rate minimization and sufficient coating reliability. Yttria-stabilized zirconia (YSZ)-reinforced AA2024 aluminum alloy was cold-sprayed onto AZ31 magnesium alloy substrates. A three-factor, five-level central composite design (CCD) with response surface methodology (RSM) was used to develop a quadratic regression model between corrosion rate and working gas temperature (WGT), nozzle spray distance (NSD), and feedstock flow rate (FFR). Analysis of variance (ANOVA) validated the high statistical significance of the model (<i>F</i> = 193.50, <i>p</i> &lt; 0.0001), high determination coefficients (<i>R</i><sup>2</sup> = 0.9792, adjusted <i>R</i><sup>2</sup> = 0.9643, predicted <i>R</i><sup>2</sup> = 0.9596), and a low coefficient of variation (7.55%). Regression diagnostics were used to test the adequacy of the model, resulting in bounded residuals within ± 4.15 and errors normally distributed. The desirability function showed a composite desirability value of 0.9625, where all three components were desired by 1.0, validating the robustness of the optimization window. Sensitivity analysis derived the parameter influence ordering as WGT &gt; NSD &gt; &gt; FFR, where WGT had the highest control. GA optimization set the optimum global at WGT = 504.44&#xa0;°C, NSD = 17.17&#xa0;mm, and FFR = 22.16&#xa0;g/min, and the corrosion rate was 1.0267&#xa0;mm/year. Microstructural analysis of the best coating exhibited a compact morphology, avoiding electrolyte permeability and providing enhanced corrosion protection. The results prove the verified GA–RSM approach to design CS process parameters that offer improved corrosion protection of lightweight Mg alloys.</p>

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Genetic Algorithm-Based Optimization of Cold-Sprayed AA2024/YSZ Composite Coating on AZ31 Magnesium Alloy

  • 期刊论文

  • 发表日期：

    2026年3月3日

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  • Ashokkumar Mohankumar,
  • Arunkumar Thirugnanasambandam,
  • Deepak Sampathkumar,
  • Anbu selvam Thilaharaj

摘要

Cold spray (CS) parameter optimization is necessary to minimize corrosion and enhance the protective properties of composite coatings on lightweight alloys. In the present work, an evolutionary genetic algorithm (GA) was used to identify the optimum combination of CS parameters and further guarantee good corrosion rate minimization and sufficient coating reliability. Yttria-stabilized zirconia (YSZ)-reinforced AA2024 aluminum alloy was cold-sprayed onto AZ31 magnesium alloy substrates. A three-factor, five-level central composite design (CCD) with response surface methodology (RSM) was used to develop a quadratic regression model between corrosion rate and working gas temperature (WGT), nozzle spray distance (NSD), and feedstock flow rate (FFR). Analysis of variance (ANOVA) validated the high statistical significance of the model (F = 193.50, p < 0.0001), high determination coefficients (R2 = 0.9792, adjusted R2 = 0.9643, predicted R2 = 0.9596), and a low coefficient of variation (7.55%). Regression diagnostics were used to test the adequacy of the model, resulting in bounded residuals within ± 4.15 and errors normally distributed. The desirability function showed a composite desirability value of 0.9625, where all three components were desired by 1.0, validating the robustness of the optimization window. Sensitivity analysis derived the parameter influence ordering as WGT > NSD > > FFR, where WGT had the highest control. GA optimization set the optimum global at WGT = 504.44 °C, NSD = 17.17 mm, and FFR = 22.16 g/min, and the corrosion rate was 1.0267 mm/year. Microstructural analysis of the best coating exhibited a compact morphology, avoiding electrolyte permeability and providing enhanced corrosion protection. The results prove the verified GA–RSM approach to design CS process parameters that offer improved corrosion protection of lightweight Mg alloys.