Process parametric optimization of spark plasma sintered Ni–Cr–ZrO2 composites using response surface methodology (RSM)

Materials properties are highly dependent on the processing parameters and technique used during sintering. The effect of Spark Plasma sintering process parameters (pressure and temperature) on the hardness and relative density of Ni–20Cr–5ZrO₂ composite was investigated. Response Surface Methodology (RSM) from the design of experiment (DOE) technique was successfully employed for the experimental design, and statistical analysis was conducted on the obtained experimental results. The microstructural analysis of the sintered composite showed the presence of solid solution phases of Ni and Cr, which were confirmed by the XRD results as (Cr,Ni) alongside unreacted ZrO₂ particles at sintering temperatures of 950 °C and 1000 °C. The validity of the model developed with the impact of each variable and their corresponding interaction on the responses was performed using analysis of variance (ANOVA). The relative density and hardness were the two responses considered. The actual values (experiment data) and expected values (simulated data) were subjected to statistical analysis, to develop a predictive model that synchronizes density and hardness as distinct process parameters, with material hardness and relative density serving as the responses of the specified experiment. For the responses, quantitative models were created, and 10 experimental runs were processed to ascertain the desirability of the responses. The SPS processing parameters considered the most desirable were 1000 °C sintering temperature and 50 MPa pressure. The hardness property obtained under this condition is 433.23 HV with a relative density of 98.15%.