Statistically designed experimental study of sol-gel based film coating scheme for high temperature super conductors and buffer materials and related manufacturing process cost evaluation

In this work, processing factors that influence the epitaxial growth of LaAlO₃ on cubic-textured nickel substrates via sol-gel route are investigated using a Taguchi L12 experimental design. Through experimental data collected on omega FWHM, phi FWHM, and composition of orientations, a set of models was generated to characterize the epitaxial growth response to the processing factors consisting of thermal processing time, temperature, atmosphere, nickel surface roughness, degree of precursor hydrolysis. withdrawal rate, and precursor solution concentration. The processing conditions are then identified that would produce the greatest degree of epitaxial growth as defined through a nondimensional term. Also, this work explores the manufacturing aspects of the sol-gel based film coating scheme through a preliminary costing study. Production objectives were assigned to be directly comparable to similar cost studies carried out for other processes such as evaporative electron beam, pulsed laser deposition, and metal organic chemical vapor deposition. Also, the final product cost was compared to an industrial goal and sensitivity of assumptions made within the study are examined in regards to meeting the goal.