In this work, wire cut electrical discharge machining (WEDM) is used for the material removing processes; it is utilized for machining conductive parts where it is required to produce complicated shapes, new profiles, new geometry, new product development, and high-accuracy components. This machining process is best suitable for high-end applications such as aerospace, automations, automobile, and medical devices. At present, most of the industrial sectors choose the WEDM process because it is used to develop products in a very short development cycle and at a better economic rate. In this paper, the selected complex geometry of the metal sample was eroded away from the wire during the WEDM process, which eliminates mechanical tensions during machining. The effect of different WEDM operation variables set as wire speed, wire tension, discharge current, dielectric flow rate, and pulse on and off time on the parameter, stainless steel 304 material removing rate (MRR) using RSM, has been studied. The MRR will be maximized if the optimum sets of operational variations are used and also achieve a superior surface finish.

Lanthanum zirconate (LZ) has emerged as a novel thermal barrier coating (TBC) material because of its higher temperature phase stability, and low sintering ability than the current standard yttria-stabilized zirconia (YSZ). In order to combine the advantages, LZ and YSZ feedstock powders are blended with predetermined weight ratios (50:50) as composite coatings. The leading issue in developing the composite coating using the atmospheric plasma spray method (APS) is finding the optimum range of input parameters to attain the desired coating properties. This issue can be resolved by developing empirical relations to find the porosity and microhardness of the coating by the atmospheric plasma spray method (APS). Spray parameters such as input power, spray distance, and powder feed rate are vital in determining the coating quality. Three variables and five levels of central composite rotatable design (CCD) to reduce the overall run of the experiment were utilized in the research. The empirical relations were predicted to find the porosity and microhardness of the specimens with APS process parameters, and the empirical relations were examined through ANOVA. Optimizing the plasma spray parameters was done using response surface methodology (RSM), which provides the minimum porosity and maximum hardness. It is validated using surface response graphs, contour plots, and overlay plots. As a result, the input power has the greatest impact on the coating properties among the three variables, and the standoff distance and powder feed rate are the subsequent important spray parameters.

Natural fibres find their way into many engineering applications in the automobile and aerospace sectors owing to their eco-friendly nature. Natural fiber produced from agricultural residue, is capable of enhancing the mechanical and thermal properties of composite materials while lowering their overall cost. The main aim of the current study is to investigate such natural fiber, nonwoven fabric reinforced composites. In this work, samples reinforced by non-woven Abutilon indicum (AI) fibre are manufactured with varying fibre weight percentages, such as 20%, 25%, 30%, 35%, 40%, using the hand layup method and needle-punching process to make the fabric and composite. Mechanical tests such as tensile, flexural, and compressive tests were using a universal testing machine, and impact tests were performed using an izod impact tester, in addition to morphological and thermal studies were performed on the above composites and their respect compositions. The effect of the fibres on FTIR and TGA was also investigated. In order to understand the bonding behaviors and the fractured composite specimens were examined by a scanning electron microscope (SEM). The findings revealed that the highest values of tensile and flexural strength were observed to be 39.796 MPa and 62.329 MPa at 35 wt% fibre and maximum impact strength and compressive strength were 0.441 joules and 47.45 Mpa at 35 wt% fibre.

Thermal barrier coatings (TBCs) enhance oxidation resistance and thermal insulation, protecting turbine blades in aero engines at high temperatures. While 8 wt.% Y₂O₃-stabilized ZrO₂ (8 YSZ) is widely used, it degrades above 1,200 °C. Lanthanum zirconate (La₂Zr₂O₇, LZ) offers better phase stability, lower sintering potential, and reduced thermal conductivity, making it a promising alternative. In this study, LZ and YSZ feedstocks were blended in weight ratios (100:0, 75:25, 50:50, 25:75) to integrate the advantages of both and applied to Inconel 718 substrates using atmospheric plasma spraying (APS). Thermal cycling at 1,100 °C was conducted to assess thermal insulation and oxidation resistance. Porosity percentages of 100 % LZ, 75 % LZ, 50 % LZ, and 25 % LZ coatings before and after thermal cycling were 9.16, 7.12, 4.45, 4.39 and 2.39, 1.63, 1.6, 1.43, respectively. The thermally grown oxide (TGO) thickness after 100 h is 10 µm, 9 µm, 6 µm, and 5 µm, respectively. Coatings with 25 % and 50 % LZ showed enhanced thermal insulation and oxidation resistance, reducing delamination due to controlled TGO growth. The 25 % LZ coating exhibited a slower oxidation rate than 100 % LZ, with improved oxygen resistance due to the pyrochlore structure, reducing TGO growth and weight gain. Incorporating YSZ into LZ coatings enhanced oxidation resistance and prolonged TBC spallation life under high-temperature conditions. This combination effectively improves TBC performance in demanding environments.