Optimizing the Thermal Spray Parameters for Producing High-Performance Mo/ZrB₂ Metal Matrix Composites Using the Taguchi Method

The process of Thermal spray is effective for creating a metal matrix composite (MMC) by embedding zirconium diboride reinforcement into a molybdenum matrix. Both materials Mo and ZrB2 have different characteristics, but they have good thermal shock resistance, maintain strength at elevated temperatures, and stability in extreme environments. The study focused on creating MoZrB2 composites using a thermal spray coating technique, varying the parameters of spraying distance, number of passes, and gas pressure, and testing the resulting castings to evaluate their hardness and Young's Modulus. The primary objective of the research was to use the Taguchi technique for identifying the optimal parameters for generating the highest Young's Modulus and hardness for the castings. The Taguchi method integrates experimental and analytical principles to identify the most significant parameter affecting the response, which can significantly enhance overall performance. The study found that the optimal parameters were a spraying distance of 20 cm, gas pressure of 6 bar, and the number of passes of 18. The Taguchi method accurately predicted the parameters that produced the highest properties for the composite coatings, which demonstrated good surface formation without hot cracks and fewer pores, with well-formed metallurgical bonding between the coating and the substrate.