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. This allows for the combination of beneficial properties in a new composite, as both materials have a high The materials Mo and ZrB2 possess different characteristics. For example, Mo has a melting point of 2622 ◦C while ZrB2 has a higher melting point of 3246 ◦C. Additionally, Mo has a high thermal conductivity of 139 W/m◦C compared to ZrB2's thermal conductivity of 24 W/m◦C. However, both materials have good thermal shock resistance, and Mo has a low coefficient of thermal expansion of 5.35 µm/m◦C while ZrB2 has a coefficient of thermal expansion of 5.8 × 10−6 K−1., as well as the ability to maintain strength at elevated temperatures and stability in extreme environments. The study focused on creating Mo/Zrb2 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.