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<p>Optimizing the thickness of thermal barrier coatings is critical for achieving enhanced heat transfer performance and thermal stability under varying thermal loading conditions. In this study, a nickel–zirconia (Ni–ZrO<sub>2</sub>) composite coating was electrodeposited on mild steel and optimized using Response Surface Methodology (RSM) based on a Central Composite Design (CCD). The optimization was carried out separately for conductive and convective heat transfer conditions to identify the most effective coating thickness. For conduction-dominated heat transfer, the optimal thickness was found to be 54.36&#xa0;µm, corresponding to a voltage of 164.66&#xa0;V, current of 0.759&#xa0;A, heat input of 51.826&#xa0;W, heat flux of 3563.17&#xa0;W/m<sup>2</sup>, and resulting surface temperature of 114.462&#xa0;°C. Under convective heat transfer conditions, the optimized thickness was 51.499&#xa0;µm, achieved at a voltage of 177.04&#xa0;V, current of 4.02&#xa0;A, heat input of 664.482&#xa0;W, heat flux of 204,659&#xa0;W/m<sup>2</sup>, air velocity of 3.381&#xa0;m/s, Reynolds number of 5722.65, and surface temperature reduced to 90.573&#xa0;°C. Computational fluid dynamics analysis confirmed uniform heat conduction with minimal thermal gradients and demonstrated the formation of a high-velocity boundary layer (0–3.30&#xa0;m/s) that enhanced convective cooling. The wall heat transfer coefficient ranged from 20.4 to 5460&#xa0;W/m<sup>2</sup>K, validating the effectiveness of the optimized coating thickness. These results establish an optimal thickness window of 50–55&#xa0;µm for Ni–ZrO<sub>2</sub> electroplated coatings, offering valuable design guidelines for thermal management applications.</p> Graphical Abstract <p></p>

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Optimization and finite element analysis of electroplated Ni–ZrO2 coatings for improved heat transfer performance

  • 期刊论文

  • 发表日期：

    2026年4月8日

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  • J. K. Manoj,
  • U. Arunachalam,
  • B. Guruprasad,
  • K. Murugan,
  • Mathanbabu Mariappan

摘要

Optimizing the thickness of thermal barrier coatings is critical for achieving enhanced heat transfer performance and thermal stability under varying thermal loading conditions. In this study, a nickel–zirconia (Ni–ZrO2) composite coating was electrodeposited on mild steel and optimized using Response Surface Methodology (RSM) based on a Central Composite Design (CCD). The optimization was carried out separately for conductive and convective heat transfer conditions to identify the most effective coating thickness. For conduction-dominated heat transfer, the optimal thickness was found to be 54.36 µm, corresponding to a voltage of 164.66 V, current of 0.759 A, heat input of 51.826 W, heat flux of 3563.17 W/m2, and resulting surface temperature of 114.462 °C. Under convective heat transfer conditions, the optimized thickness was 51.499 µm, achieved at a voltage of 177.04 V, current of 4.02 A, heat input of 664.482 W, heat flux of 204,659 W/m2, air velocity of 3.381 m/s, Reynolds number of 5722.65, and surface temperature reduced to 90.573 °C. Computational fluid dynamics analysis confirmed uniform heat conduction with minimal thermal gradients and demonstrated the formation of a high-velocity boundary layer (0–3.30 m/s) that enhanced convective cooling. The wall heat transfer coefficient ranged from 20.4 to 5460 W/m2K, validating the effectiveness of the optimized coating thickness. These results establish an optimal thickness window of 50–55 µm for Ni–ZrO2 electroplated coatings, offering valuable design guidelines for thermal management applications.

Graphical Abstract