Fabrication and Microstructural Analysis of SUS316-Al2O3 Functionally Graded Beams Manufactured using Plasma Thermal Spray Technique

This study investigates the development of functionally graded materials (FGMs) designed to possess a combination of high temperature resistance and high strength, with potential applications in defense, aerospace, energy, and medical sectors. Specifically, the research focuses on fabricating functionally graded beams composed of SUS316 and Al2O3 using the plasma spraying technique with ceramic content varying from 0 to 40% at the outermost surface. The research involves parametric optimization to determine the ideal process parameters for FGM beam fabrication. Potential defects such as porosity and voids identified during sample preparation were addressed through targeted corrective measures, including controlling the relative speed of the spray gun and adjusting the coating thickness with each pass. A detailed microstructural analysis, conducted using scanning electron microscopy, reveals a layered gradation of materials within the plasma-sprayed beams, with distinct distribution patterns of the constituent elements.