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.

---

In this experiment, Stainless steel type 316 was utilized as the substrate. To prepare samples, the substrate was cut using an abrasive cutter, resulting in dimensions of 3 x 2.5 x 0.3 cm. Next, the samples were polished using P 120, 400, 800, 1000 and 1200 grit to remove dust and carbon from the surface, and the composition of the substrate contains some coating materials such as molybdenum. For the ceramic top-coat material, molybdenum and zirconium diboride powders with the same weight ratios were employed. The wt. % of both powders was maintained at 50 wt. %. To obtain the desired particle size, the molybdenum and zirconium diboride powders were separately sieved using a sieve shaker for 1 h each. The powders were then ball milled at 121 rpm for 4 h using a roller ball mill for homogeneous mixing.

---

Advancement in Material Science: It highlights the importance of optimizing TS process parameters to enhance coating properties, which can lead to advancements in materials engineering and surface technology.

Optimization Techniques: By utilizing the Taguchi method, the article demonstrates a systematic approach to optimize manufacturing processes. This method's application in determining the optimal TS parameters can be extended to other manufacturing processes, promoting efficiency and quality improvement in various fields.

Industry Applications: Improved coatings can lead to enhanced durability, performance, and lifespan of critical components, which can have substantial economic benefits for these industries.

Environmental and Economic Benefits: The article's insights into optimizing coatings for better performance can lead to more sustainable manufacturing practices.

Enhanced Performance: The article provides detailed insights into optimizing TS parameters to achieve coatings with superior hardness, wear resistance, and other mechanical properties. This can result in components that perform better under extreme conditions, such as high temperatures and corrosive environments.

Cost-Effectiveness: The use of the Taguchi method ensures that the manufacturing process is efficient and cost-effective, with reduced trial-and-error and wastage.

Quality Improvement: By identifying the most influential parameters and optimizing them, the quality of the coatings can be significantly improved. This leads to more reliable and consistent products, which is critical for industries with stringent quality requirements.

---

This study aimed to optimize the hardness and Young's Modulus of a MoZrB2 composite coating by varying different deposition parameters. The Taguchi method was used to evaluate these parameters, and a confirmation experiment was conducted to validate the results [37]. The surface morphology of the coatings produced was also analyzed to determine their impact on tribological and hardness properties. The study revealed the optimal deposition parameter levels required to produce a MoZrB2 composite coating with high hardness and a high Young's Modulus. The optimal spraying distance, gas pressure, and number of passes for high hardness were 20 cm, 6 bar, and 18, respectively, while for the high Young's Modulus, they were 25 cm, 2 bar, and 12, respectively. The scanning electron microscope (SEM) (TESCAN VEGA's 4th generation, Kohoutovice, Czech Republic) micrographs in Figure 8 showed that the coatings had laminar structures consisting of stacked particles and pores resulting from the short time of the material in the flame and the high cooling rate of the molten material during the coating's formation. The SEM of the coatings displayed stacked splats as well as defects from the technique, such as pores, cavities, oxides, and splat boundaries.

Aerospace Industry: Metal matrix composites (MMCs) are essential in aerospace applications due to their high strength-to-weight ratio, thermal stability, and corrosion resistance. The aerospace sector is consistently growing, driven by increasing demand for commercial aircraft, defense spending, and advancements in space exploration.

Power Generation: The power generation industry requires materials that can withstand high temperatures and harsh environments. MMCs and TS coatings provide the necessary durability and performance, making them valuable in this sector. The growth in renewable energy projects and the need for efficient power generation technologies will drive demand.

Heavy Machinery: Heavy machinery and industrial equipment benefit from the enhanced wear resistance and mechanical properties of MMCs and TS coatings. The construction, mining, and manufacturing industries' expansion will support market growth in this segment.

Optimization Techniques: The use of the Taguchi method for optimizing TS process parameters indicates a focus on improving manufacturing efficiency and product quality. This approach enhances the market appeal by ensuring consistent and high-performing coatings, which is crucial for industries with stringent performance requirements.

Research and Development: Continuous R&D efforts, as highlighted in the article, indicate ongoing innovation in developing advanced MMCs and TS coatings. This positions the technology for sustained growth as new applications and improved materials are discovered.