The present investigation focuses on the study of erosive slurry wear behaviour of plasma-sprayed flyash–Al2O3 composite coatings on the substrate of Al6061 alloy in slurry with 3.5% NaCl solution. The influence of various process parameters, such as different slurry concentration (10–30%), varying rotational speed (500–1500 rev min−1) and varied impinging particle sizes (210–425 µm), was compared by conventional weight loss method and Taguchi's L27 experimental design method. It was observed that the composite coatings on Al6061 alloy showed a highest resistance to erosion. The significance of the parameters was determined by using analysis of variance technique and it was found that the factors slurry concentration and slurry speed had great influence on erosive slurry wear of substrate with and without plasma spray coatings. Regression analysis was used to develop mathematical model to predict the slurry erosive wear. Predicted values are in good agreement with experimental values.
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