Thermal spray coatings for electromagnetic wave absorption and interference shielding: a review and future challenges

Journal article


Faisal, N.H., Ahmed, R., Sellami, N., Prathuru, A., Njuguna, J., Venturi, F., Hussain, T., Nezhad, H.Y., Kumar, N., Goel, S., Upadhyaya, H., Joshi, S., Muhammad-Sukki, F., Prabhu, R., Mallick, T., Whittow, W. and Kamnis, S. (2022). Thermal spray coatings for electromagnetic wave absorption and interference shielding: a review and future challenges. Advanced Engineering Materials. https://doi.org/10.1002/adem.202200171
AuthorsFaisal, N.H., Ahmed, R., Sellami, N., Prathuru, A., Njuguna, J., Venturi, F., Hussain, T., Nezhad, H.Y., Kumar, N., Goel, S., Upadhyaya, H., Joshi, S., Muhammad-Sukki, F., Prabhu, R., Mallick, T., Whittow, W. and Kamnis, S.
Abstract

This review paper aims to consolidate scattered literature on thermally sprayed coatings with non-ionising electromagnetic (EM) wave absorption and shielding over specific wavelengths potentially useful in diverse applications (e.g., microwave to millimeter wave, solar selective, photocatalytic, interference shielding, thermal barrier-heat/emissivity). Materials EM properties such as electric permittivity, magnetic permeability, electrical conductivity, and dielectric loss are critical due to which a material can respond to absorbed, reflected, transmitted, or may excite surface electromagnetic waves at frequencies typical of electromagnetic radiations. Thermal spraying is a standard industrial practice used for depositing coatings where the sprayed layer is formed by successive impact of fully or partially molten droplets/particles of a material (used in the form of powder or wire) exposed to high or moderate temperatures and velocities. However, as an emerging novel application of an existing thermal spray techniques, some special considerations are warranted for targeted development involving relevant characterisation. Key potential research areas of development relating to material selection and coating fabrication strategies and their impact on existing practices in the field are identified. The study shows a research gap in the feedstock materials design and doping (including hollow and yolk-shelled structure types) and their complex selection covered by thermally sprayed coatings that can be critical to advancing applications exploiting their electromagnetic properties

Keywordselectromagnetic wave; radiation; thermal spray coatings; absorption; solar; photocatalytic; heat; emissivity; interference; shielding.
Year2022
JournalAdvanced Engineering Materials
PublisherWiley
ISSN1438-1656
Digital Object Identifier (DOI)https://doi.org/10.1002/adem.202200171
Web address (URL)https://onlinelibrary.wiley.com/journal/15272648
Publication dates
Print25 Mar 2022
Publication process dates
Accepted21 Mar 2022
Deposited23 Mar 2022
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Open
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The Critical Raw Materials in Cutting Tools for Machining Applications: A Review
Goel, S. (2020). The Critical Raw Materials in Cutting Tools for Machining Applications: A Review. Materials MDPI. 13 (1377). https://doi.org/10.3390/ma13061377
An experimental study on lap joining of multiple sheets of aluminium alloy (AA 5754) using friction stir spot welding
Goel, S., Zlatanovic DL and Balos S (2020). An experimental study on lap joining of multiple sheets of aluminium alloy (AA 5754) using friction stir spot welding. International Journal of Advanced Manufacturing Technology. 107, pp. 3093-3107. https://doi.org/10.1007/s00170-020-05214-z
Towards an improved understanding of plasticity, friction and wear mechanisms in precipitate containing AZ91 Mg alloy
Kumar D, Goel, S., Gosvami N and Jain J (2020). Towards an improved understanding of plasticity, friction and wear mechanisms in precipitate containing AZ91 Mg alloy. Materialia. 10, p. 100640. https://doi.org/10.1016/j.mtla.2020.100640
Functional evaluation and testing of a newly developed Teleost’s Fish Otolith derived biocomposite coating for healthcare
Goel, S, Montanez, N. D., Carreno, H., Escobar, P., Estupinan, H. A., Pena, D. Y. and Endrino, J. L. (2020). Functional evaluation and testing of a newly developed Teleost’s Fish Otolith derived biocomposite coating for healthcare. Scientific Reports. 10 (1), pp. 1-16. https://doi.org/10.1038/s41598-019-57128-w
Fused deposition modeling-based additive manufacturing (3D printing): techniques for polymer material systems
Daminabo, S. C., Goel, S, Grammatikos, S. A., Nezhad, H. Y. and Thakur, V. K. (2020). Fused deposition modeling-based additive manufacturing (3D printing): techniques for polymer material systems. Materials Today Chemistry. 16, p. 100248. https://doi.org/10.1016/j.mtchem.2020.100248
On the Use of the Theory of Critical Distances with Mesh Control for Fretting Fatigue Lifetime Assessment
Zabala, A., Infante-Garcia, Giner, E., Goel, S., Endrino, J.L. and Llavori, I. (2020). On the Use of the Theory of Critical Distances with Mesh Control for Fretting Fatigue Lifetime Assessment . Tribology International. 142, p. 105985. https://doi.org/https://doi.org/10.1016/j.triboint.2019.105985
Ultra-Low Temperature CO Oxidation Activity of Octahedral Site Cobalt Species in Co3O4 Based Catalysts: Unravelling the Origin of Unique Catalytic Property
Baidya, T., Murayama, T., Nellaiappan, S., Kumar, N., Bera, P., Safonova, O., Lin, M., Priolkar, K.R., Kundo, S., Rao, B.S., Steiger, P., Sharma, S., Biswas, K., Pradhan, S.K., Lingaiah, N., Malviya, K.D. and Hatura, M. (2019). Ultra-Low Temperature CO Oxidation Activity of Octahedral Site Cobalt Species in Co3O4 Based Catalysts: Unravelling the Origin of Unique Catalytic Property. The Journal of Physical Chemistry C. https://doi.org/10.1021/acs.jpcc.9b04136
Benchmarking of several material constitutive models for tribology, wear, and other mechanical deformation simulations of Ti6Al4V
Liu C, Goel S, Llavori I, Stolf P, Giusca CL, Zabala A, Kohlscheen J, Paiva JM, Endrino JL and Veldhuis SC Fox Rabinovich GS (2019). Benchmarking of several material constitutive models for tribology, wear, and other mechanical deformation simulations of Ti6Al4V. Journal of the Mechanical Behavior of Biomedical Materials. 97, pp. 126-137. https://doi.org/10.1016/j.jmbbm.2019.05.013
Optical analysis of RF sputtering plasma through colour characterization
Salimian, A., Haghpanahan, R., Hasnath, A. and Upadhyaya, H. (2019). Optical analysis of RF sputtering plasma through colour characterization. Coatings. 9 (5), pp. 315-315. https://doi.org/10.3390/coatings9050315
Ambient stable, hydrophobic, electrically conductive porphyrin hole-extracting materials for printable perovskite solar cells
Reddy, G., Katakam, R., Devulapally, K., Jones, L.A., Della Gaspera, E., Upadhyaya, H.M., Islavath, N. and Giribabu, L. (2019). Ambient stable, hydrophobic, electrically conductive porphyrin hole-extracting materials for printable perovskite solar cells. Journal of Materials Chemistry C. 7 (16), pp. 4702-4708. https://doi.org/10.1039/c9tc00605b
Cryomilling: An environment friendly approach of preparation large quantity ultra refined pure aluminium nanoparticles
Kumar, N. and Biswas, K. (2019). Cryomilling: An environment friendly approach of preparation large quantity ultra refined pure aluminium nanoparticles. Journal of Materials Research and Technology. 8 (1), pp. 63-74. https://doi.org/10.1016/j.jmrt.2017.05.017
Stabilization of a Highly Concentrated Colloidal Suspension of Pristine Metallic Nanoparticles
Kumar, N., Biswas, K., Tiwary, C.S., Machado, L.D. and Gupta, R.K. (2019). Stabilization of a Highly Concentrated Colloidal Suspension of Pristine Metallic Nanoparticles. Langmuir. 35 (7), pp. 2668-2673. https://doi.org/10.1021/acs.langmuir.8b03401
The Effect of Configurational Entropy of Mixing on the Design and Development of Novel Materials
Biswas, K. and Kumar, N. (2019). The Effect of Configurational Entropy of Mixing on the Design and Development of Novel Materials. Proceedings of the Indian National Science Academy. 86 (3), pp. 1127-1134. https://doi.org/10.16943/ptinsa/2019/49674
Optimizing room temperature binder free TiO2 paste for high efficiency flexible polymer dye sensitized solar cells
Kishore Kumar, D, Hsu, MH, Ivaturi, A, Chen, B, Bennett, N and Upadhyaya, HM (2019). Optimizing room temperature binder free TiO2 paste for high efficiency flexible polymer dye sensitized solar cells. Flexible and Printed Electronics. 4 (1), pp. 015007-015007. https://doi.org/10.1088/2058-8585/ab02c4
Low-temperature titania-graphene quantum dots paste for flexible dye-sensitised solar cell applications
Kumar, DK, Suazo-Davila, D, García-Torres, D, Cook, NP, Ivaturi, A, Hsu, MH, Martí, AA, Cabrera, CR, Chen, B, Bennett, N and Upadhyaya, HM (2019). Low-temperature titania-graphene quantum dots paste for flexible dye-sensitised solar cell applications. Electrochimica Acta. 305, pp. 278-284. https://doi.org/10.1016/j.electacta.2019.03.040
Scalable screen-printing manufacturing process for graphene oxide platinum free alternative counter electrodes in efficient dye sensitized solar cells
Kumar, DK, Swami, SK, Dutta, V, Chen, B, Bennett, N and Upadhyaya, HM (2019). Scalable screen-printing manufacturing process for graphene oxide platinum free alternative counter electrodes in efficient dye sensitized solar cells. FlatChem. 15, pp. 100105-100105. https://doi.org/10.1016/j.flatc.2019.100105
Screen printed tin selenide films used as the counter electrodes in dye sensitized solar cells
Kishore Kumar, D, Popuri, SR, Swami, SK, Onuoha, OR, Bos, JW, Chen, B, Bennett, N and Upadhyaya, HM (2019). Screen printed tin selenide films used as the counter electrodes in dye sensitized solar cells. Solar Energy. 190, pp. 28-33. https://doi.org/10.1016/j.solener.2019.07.066
Fabrication of functionalised surfaces on Gum metal (Ti-30Nb) using micromachining
Hawi, S., Dickins, A., Pardal, G.R., Giusca, C., Pearce, O. and Goel, S. (2019). Fabrication of functionalised surfaces on Gum metal (Ti-30Nb) using micromachining . euspen’s 19th International Conference & Exhibition, Bilbao, ES, June 2019. Bilbao 03 - 07 Jun 2019 EUSPEN.
Suppressing the Use of Critical Raw Materials in Joining of AISI 304 Stainless Steel Using Activated Tungsten Inert Gas Welding
Balos, S., Dramicanin, M., Janjatovic, P., Zabunov, I., Pilic, B., Goel, S. and Szutkowska, M. (2019). Suppressing the Use of Critical Raw Materials in Joining of AISI 304 Stainless Steel Using Activated Tungsten Inert Gas Welding. Metals. 9 (11), p. 1187. https://doi.org/https://doi.org/10.3390/met9111187
The role of high-pressure coolant in the wear characteristics of WC-Co tools during the cutting of Ti–6Al–4V
Stolf, P., Paiva, J.M., Ahmed, Y.S., Endrina, J.L., Goel, S. and Veldhuis, S.C. (2019). The role of high-pressure coolant in the wear characteristics of WC-Co tools during the cutting of Ti–6Al–4V. Wear. 440-441, p. 203090. https://doi.org/10.1016/j.wear.2019.203090
Molecular dynamics simulation of the elliptical vibration assisted machining (EVAM) of pure iron
Goel S, Martinez FD, Chavoshi SZ, Khatri N and Giusca C (2018). Molecular dynamics simulation of the elliptical vibration assisted machining (EVAM) of pure iron. Journal of Micromanufacturing. 1 (1), pp. 6-19. https://doi.org/10.1177/2516598418765359
The possibility of performing FEA analysis of a contact loading process fed by the MD simulation data
Goel S, Iñigo Llavori AZ, Giusca C, Veldhuis SC and Endrino JL (2018). The possibility of performing FEA analysis of a contact loading process fed by the MD simulation data. International Journal of Machine Tools and Manufacture. 134, pp. 79-80. https://doi.org/10.1016/j.ijmachtools.2018.07.003
Preparation of nanocrystalline high-entropy alloys via cryomilling of cast ingots
Kumar, N., Tiwary, C. and Biswas, K. (2018). Preparation of nanocrystalline high-entropy alloys via cryomilling of cast ingots. Journal of Materials Science. 53 (19), pp. 13411-13423. https://doi.org/10.1007/s10853-018-2485-z
Effect of Al Addition on the Microstructural Evolution of Equiatomic CoCrFeMnNi Alloy
Kumar, J., Kumar, N., Das, S., Gurao, N. and Biswas, K. (2018). Effect of Al Addition on the Microstructural Evolution of Equiatomic CoCrFeMnNi Alloy. Transactions of the Indian Institute of Metals. 71 (11), pp. 2749-2758. https://doi.org/10.1007/s12666-018-1443-4
Incipient plasticity in tungsten during nanoindentation: Dependence on surface roughness, probe radius and crystal orientation
Beake B and Goel, S. (2018). Incipient plasticity in tungsten during nanoindentation: Dependence on surface roughness, probe radius and crystal orientation. International Journal of Refractory Metals and Hard Materials. 75, pp. 63-69. https://doi.org/https://doi.org/10.1016/j.ijrmhm.2018.03.020
Designing nanoindentation simulation studies by appropriate indenter choices: Case study on single crystal tungsten
Goel, S., Cross, G., Stukowski, A., Gamsjager, E., Beake, B. and Agrawal, A. (2018). Designing nanoindentation simulation studies by appropriate indenter choices: Case study on single crystal tungsten. Computational Materials Science. 152, pp. 196-210. https://doi.org/https://doi.org/10.1016/j.commatsci.2018.04.044
Low-Temperature CO Oxidation over Combustion Made Fe- and Cr-Doped Co3O4 Catalysts: Role of Dopant’s Nature toward Achieving Superior Catalytic Activity and Stability
Baidya, T., Murayama, P., Bera, P., Safonova, O.V., Steiger, P., Kumar, N., Biswas, K. and Haruta, M. (2017). Low-Temperature CO Oxidation over Combustion Made Fe- and Cr-Doped Co3O4 Catalysts: Role of Dopant’s Nature toward Achieving Superior Catalytic Activity and Stability. The Journal of Physical Chemistry C. 121 (28), p. 15256–15265. https://doi.org/10.1021/acs.jpcc.7b04348
Current trends and future of sequential micro-machining processes on a single machine tool
Chavoshi, S.Z., Goel, S. and Morantz, P. (2017). Current trends and future of sequential micro-machining processes on a single machine tool. Materials & Design. 127, pp. 37-53. https://doi.org/10.1016/j.matdes.2017.04.057
Cyclic nanoindentation and nano-impact fatigue mechanisms of functionally graded TiN/TiNi film
Faisal NH, Prathuru AK, Goel S, Ahmed R, Droubi MG, Beake BD and Fu YQ (2017). Cyclic nanoindentation and nano-impact fatigue mechanisms of functionally graded TiN/TiNi film. Shape Memory and Superelasticity. 3, pp. 149-167. https://doi.org/10.1007/s40830-017-0099-y
Addressing the discrepancy of finding equilibrium melting point of silicon using MD simulations
Chavoshi SZ, Xu S and Goel S (2017). Addressing the discrepancy of finding equilibrium melting point of silicon using MD simulations. Proceedings of the Royal Society A: Mathematical, Physical and Engineering Sciences. https://doi.org/10.1098/rspa.2017.0084
Influence of temperature on the anisotropic cutting behaviour of single crystal silicon: A molecular dynamics simulation investigation
Chavoshi, S.Z., Goel, S. and Luo, X. (2016). Influence of temperature on the anisotropic cutting behaviour of single crystal silicon: A molecular dynamics simulation investigation. Journal of Manufacturing Processes. 23, pp. 201-210. https://doi.org/10.1016/j.jmapro.2016.06.009
Advances in the surface defect machining (SDM) of hard steels
Rashid, W.B. and Goel, S. (2016). Advances in the surface defect machining (SDM) of hard steels. Journal of Manufacturing Processes. 23, pp. 37-46. https://doi.org/10.1016/j.jmapro.2016.05.007
Influence of microstructure on the cutting behaviour of silicon
Goel, S., Kovalchenko, A., Stukowski, A. and Cross, G. (2016). Influence of microstructure on the cutting behaviour of silicon. Acta Materialia. 105, pp. 464-478. https://doi.org/10.1016/j.actamat.2015.11.046
Investigating the emission characteristics of single crystal YAG when activated by high power laser beams
Salimian, A, Silver, J, Fern, GR, Upadhyaya, H, Metcalfe, A, Ireland, TG, Harris, P and Haghpanahan, R (2016). Investigating the emission characteristics of single crystal YAG when activated by high power laser beams. ECS Journal of Solid State Science and Technology. 5 (10), pp. R172-R177. https://doi.org/10.1149/2.0271610jss
Laser diode induced lighting modules
Salimian, A., Fern, G.R., Upadhyaya, H. and Silver, J. (2016). Laser diode induced lighting modules. ECS Journal of Solid State Science and Technology. 5 (3), pp. R26-R33. https://doi.org/10.1149/2.0101603jss
Green synthesis of Ag nanoparticles in large quantity by cryomilling
Kumar, N., Biswas, K. and Gupta, R. K. (2016). Green synthesis of Ag nanoparticles in large quantity by cryomilling. RSC Advances. 6 (112), pp. 111380-111388. https://doi.org/10.1039/c6ra23120a
High mobility titanium-doped indium oxide for use in tandem solar cells deposited via pulsed DC magnetron sputtering
Grew, B, Bowers, JW, Lisco, F, Arnou, N, Walls, JM and Upadhyaya, HM (2014). High mobility titanium-doped indium oxide for use in tandem solar cells deposited via pulsed DC magnetron sputtering. Energy Procedia. 60 (C), pp. 148-155. https://doi.org/10.1016/j.egypro.2014.12.357
Design and optimisation of process parameters in an in-line CIGS evaporation pilot system
Wei, Z., Bobbili, P.R., Senthilarasu, S., Shimell, T. and Upadhyaya, H.M. (2014). Design and optimisation of process parameters in an in-line CIGS evaporation pilot system. Surface & Coatings Technology. 241, pp. 159-167. https://doi.org/10.1016/j.surfcoat.2013.10.033
Spray deposited copper zinc tin sulphide (Cu<inf>2</inf>ZnSnS<inf>4</inf>) film as a counter electrode in dye sensitized solar cells
Swami, S.K., Chaturvedi, N., Kumar, A., Chander, N., Dutta, V., Kumar, D.K., Ivaturi, A., Senthilarasu, S. and Upadhyaya, H.M. (2014). Spray deposited copper zinc tin sulphide (Cu<inf>2</inf>ZnSnS<inf>4</inf>) film as a counter electrode in dye sensitized solar cells. Physical Chemistry Chemical Physics. 16 (43), pp. 23993-23999. https://doi.org/10.1039/c4cp03312d