Large-scale manufacturing route to metamaterial coatings using thermal spray techniques and their response to solar radiation
Large-scale manufacturing route to metamaterial coatings using thermal spray techniques and their response to solar radiation
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DOI：
10.1007/s42247-021-00252-z
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发表时间：
2021-07
影响因子：
3.8
通讯作者：
N. Faisal;N. Sellami;F. Venturi;T. Hussain;T. Mallick;F. Muhammad-Sukki;Alex Bishop;H. Upadhyaya;N. K. Katiyar;S. Goel
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文献类型：
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作者：
N. Faisal;N. Sellami;F. Venturi;T. Hussain;T. Mallick;F. Muhammad-Sukki;Alex Bishop;H. Upadhyaya;N. K. Katiyar;S. Goel
超材料是一种人工周期性二维或三维结构，可以改变电磁波的传播特性（即反射、透射、吸收）。目前超材料涂层领域面临的挑战是其大规模、大长度的制造。显然需要增强这些技术的工艺技术和可扩展性。热喷涂是一种用于沉积小到大规模涂层的方法，其中喷涂层通常是通过暴露在各种工艺条件下的材料的完全或部分熔融颗粒的连续冲击而形成的。这项工作旨在研究使用热喷涂技术制造大规模超材料涂层的可行性，并检查它们对太阳辐射的响应。将两种类型的涂层（即 Cr2O3 和 TiO2）沉积到各种基材（例如钢、铝、玻璃、氧化铟锡 (ITO) 涂层玻璃）上，并使用细丝网（143 µm 和 1 mm 孔径尺寸）作为掩模板，使用悬浮高速氧燃料热喷涂 (S-HVOF) 和大气来操纵表面图案 分别采用等离子喷涂（APS）方法。沉积后，表征了它们对电磁波（250 至 2500 nm 或紫外线 (UV)-可见光 (Vis)-红外线 (IR) 区域）的响应。使用扫描电子显微镜 (SEM)、能量色散 X 射线光谱 (EDS)、X 射线衍射 (XRD)、三维轮廓测定法和光学光谱法进行额外的微观结构表征。事实证明，通过热喷涂技术的新颖应用，大规模制造超材料涂层是可能的，并且这种材料可以影响电磁波传播。铝基板上的 Cr2O3 和 TiO2 涂层之间的比较表明，Cr2O3 涂层（对于 1 毫米孔径尺寸）在整个光谱范围内的反射率降低了三个数量级。结论是，对于相似的带隙，铝基板上的 Cr2O3 涂层将比 TiO2 涂层产生更好的光学性能，因此更适用于制造光电器件。图形摘要
Metamaterials, an artificial periodic two- or three-dimensional configuration, can change propagation characteristics of electromagnetic waves (i.e., reflection, transmission, absorption). The current challenges in the field of metamaterial coatings are their manufacturing in a large-scale and large-length scale. There is a clear need to enhance process technologies and scalability of these. Thermal spraying is a method used to deposit small- to large-scale coatings where the sprayed layer is typically formed by the successive impact of fully or partially molten particles of a material exposed to various process conditions. This work aims to investigate the feasibility to manufacture large scale metamaterial coatings using the thermal spray technique and examine their response to solar radiation. Two types of coatings namely, Cr2O3and TiO2, were deposited onto various substrates (e.g., steel, aluminium, glass, indium tin oxide (ITO)–coated glass) with a fine wire mesh (143 µm and 1 mm aperture sizes) as the masking sheet to manipulate the surface pattern using suspension high-velocity oxy-fuel thermal spraying (S-HVOF) and atmospheric plasma-sprayed (APS) methods, respectively. Post deposition, their responses subjected to electromagnetic wave (between 250 and 2500 nm or ultraviolet (UV)-visible (Vis)-infrared (IR) region) were characterised. The additional microstructural characterisation was performed using scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), X-ray diffraction (XRD), three-dimensional profilometry, and optical spectroscopy. It is demonstrated that through novel application of thermal spray techniques, large-scale manufacturing of metamaterial coating is possible, and such material can affect electromagnetic wave propagation. Comparison between Cr2O3and TiO2coatings on aluminium substrates showed reduced three orders of reduced reflectance for Cr2O3coatings (for 1-mm aperture size) throughout the spectrum. It was concluded that for a similar bandgap, Cr2O3coatings on aluminium substrate will yield improved optical performance than TiO2coating, and hence more useful to fabricate opto-electronic devices.Graphical abstract