AI-enhanced multi-objective optimization of plasma-sprayedhybrid coatings for microsatellite shells

Authors

  • Vũ Dương School of Engineering and Technology, Duy Tan University, 03 Quang Trung, Hai Chau, Da Nang, Vietnam
  • Nguyễn Đức Hoàng A. Faculty of Mechanical Engineering, room 102D, 120 Hoang Minh Thao, Duy Tan University, Da Nang, Vietnam
  • Đặng Nguyễn Uyên Phương Faculty of Mechanical Engineering, room 102D, 120 Hoang Minh Thao, Duy Tan University, Da Nang, Vietnam

DOI:

https://doi.org/10.17308/kcmf.2026.28/13974

Keywords:

Plasma spray, AI optimization, Microsatellite coatings, Duralumin alloy

Abstract

Objectives: Small spherical satellites operating in low Earth orbit (LEO, 400–800 km altitude) require lightweight and highly durable shells capable of resisting extreme mechanical, thermal, and radiative stresses. Typically ranging from 0.4 m to 1.0 m in diameter, these micro-spherical platforms serve essential functions such as Earth observation, space environment sensing, communications calibration, and atmospheric monitoring. However, their exposed surfaces suffer from atomic oxygen (AO) erosion, ultraviolet radiation, and micrometeoroid impacts, severely limiting mission lifespan and reliability. To address these challenges, this study proposes an AI-assisted multi-iteration optimization framework integrating plasma spray process modeling with hybrid material design for spherical aluminum-copper-magnesium (duralumin) shells.

Experimental: Thirty peer-reviewed studies were analyzed to establish design boundaries and parameter ranges for plasma temperature, spray velocity, standoff distance, and scanning speed. A multi-objective genetic algorithm (MOGA) was employed to co-optimize substrate composition and deposition conditions, minimizing porosity and maximizing adhesion. The resulting multilayer coating (NiCrAlY bond coat / Al2O3-13TiO2 / ZrO2-8Y2O3/ SiOx-DLC top layer) achieved a porosity of 3.7 %, adhesion strength of 68 MPa, and thermal stability up to 980 °C. Finite element and microstructural analyses revealed dense lamellar interfaces and low residual stresses, confirming superior AO and UV resistance.

Conclusions: This research highlights the critical role of small spherical satellites as compact yet strategic assets in modern aerospace infrastructure. Given their technical complexity, only a limited number of advanced nations and global corporations currently possess the capability to design, manufacture, and launch such intelligent microsatellite systems

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Author Biographies

  • Vũ Dương, School of Engineering and Technology, Duy Tan University, 03 Quang Trung, Hai Chau, Da Nang, Vietnam

    Associate Professor, Vice Dean, School of Engineering and Technology, Duy Tan University (Da Nang city, Viet Nam)

  • Nguyễn Đức Hoàng A., Faculty of Mechanical Engineering, room 102D, 120 Hoang Minh Thao, Duy Tan University, Da Nang, Vietnam

    MSc, Instructor, School of Engineering and Technology, Duy Tan University (Da Nang city, Viet Nam)

  • Đặng Nguyễn Uyên Phương, Faculty of Mechanical Engineering, room 102D, 120 Hoang Minh Thao, Duy Tan University, Da Nang, Vietnam

    MSc ,Instructor, School of Engineering and Technology, Duy Tan University ,Da Nang city , Viet Nam

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Published

2026-09-22

Issue

Vol. 28 No. 3 (2026)

Section

Short communication

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Copyright (c) 2026 Kondensirovannye sredy i mezhfaznye granitsy = Condensed Matter and Interphases

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How to Cite

AI-enhanced multi-objective optimization of plasma-sprayedhybrid coatings for microsatellite shells. (2026). Kondensirovannye Sredy I Mezhfaznye Granitsy = Condensed Matter and Interphases, 28(3), 449-456. https://doi.org/10.17308/kcmf.2026.28/13974