Mathematical–Statistical Nonlinear Model of Zincing Process and Strategy for Determining the Optimal Process Conditions

Abstract

The article is aimed at the mathematical and optimization modeling of technological processes of surface treatments, specifically the zincing process. In surface engineering, it is necessary to eliminate the risk that the resulting product quality will not be in line with the reliability requirements or needs of customers. To date, a number of research studies deal with the applications of mathematical modeling and optimization methods to control technological processes and eliminate uncertainties in the technological response variables. The situation is somewhat different with the acid zinc plating process, and we perceive their lack more. This article reacts to the specific requirements from practice for the prescribed thickness and quality of the zinc layer deposited in the acid electrolyte, which stimulated our interest in creating a statistical nonlinear model predicting the thickness of the resulting zinc coating (ZC). The determination of optimal process conditions for acid galvanizing is a complex problem; therefore, we propose an effective solving strategy based on the (i) experiment performed by using the design of experiments (DOE) approach; (ii) exploratory and confirmatory statistical analysis of experimentally obtained data; (iii) nonlinear regression model development; (iv) implementation of nonlinear programming (NLP) methods by the usage of MATLAB toolboxes. The main goal is achieved—regression model for eight input variables, including their interactions, is developed (the coefficient of determination reaches the value of R2 = 0.959403); the optimal values of the factors acting during the zincing process to achieve the maximum thickness of the resulting protective zinc layer (the achieved optimum value th* = 12.7036 μm), are determined.