It is predicted that the thickness of a coating has major effects on a substrate in terms of mechanical and thermal properties. In this study, an Al2O3-ZrO2-SiO2 slurry was prepared as a coating material, which formed an alumina-zirconia-mullite composite coating after sintering. The alumina-zirconia-mullite composite coating was coated on a zirconia substrate to generate compressive stress in the coating due to the mismatch of the coefficient of thermal expansion (CTE). A series of coated samples with different coating thicknesses from ∼10 μm to ∼200 μm were prepared to investigate the effects of coating thickness. The residual compressive stress, thermal conductivity, CTE, and Young's modulus of the coating material were determined by relative methods, and the flexural strength of the coated and uncoated samples was measured by 3-point bending. The strength of the coated samples was 1362.98 ± 30.29 MPa, which is a 54.07% enhancement compared to the uncoated samples. The thermal conductivity of the coated samples was also increased compared to that of the uncoated samples. For a given thickness of the substrate of 2 mm, there was an optimum thickness of the coating of 90 μm, which showed the greatest strength compared to the other samples. Coatings that were too thin or too thick did not show the best reinforcement. Moreover, the porosity of the coated samples was also determined and discussed in this study. Comparison samples without SiO2 were also manufactured, and their flexural strength and thermal conductivity were found to not be as good as the samples with SiO2.
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