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Ceramics International 47 (2021) 17337–17344

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Ceramics International
journal homepage: www.elsevier.com/locate/ceramint

Thermally stable ultra-thin and refractory microwave absorbing coating


Shixin Zhao, Hua Ma *, Tengqiang Shao, Jun Wang **, Lei Zhang, Sai Sui, Mingde Feng,
Jiafu Wang, Shaobo Qu
Department of Basic Sciences, Air Force Engineering University, Xi’an, 710051, China

A R T I C L E I N F O A B S T R A C T

Keywords: The thickness and thermal stability of electromagnetic (EM) wave absorbing materials greatly affect its service
EM absorbing material life and practical application. In this paper, an ultra-thin high-temperature EM wave absorbing coating composed
TiB2 material of titanium diboride (TiB2) and alumina (Al2O3) was designed and experimentally demonstrated, which exhibits
X-band
excellent absorbing performance in a wide temperature range. Atmospheric plasma spraying (APS) technique
Atmospheric plasma spraying
was employed to simplify the preparation of the coating, ensuring its feasibility and practicability. Due to its
permittivity increases with temperature and TiB2 content, the coating can exhibit good EM impedance in a wide
temperature range by adjusting the suitable ratio of the x.wtTiB2~(1-x).wtAl2O3. When the x value is equal to
0.3, with a thickness of only 1.4 mm, the reflection loss (RL) below -5 dB covered almost the whole X-band in a
wide temperature range from 400 ◦ C to 800 ◦ C. The results of X-ray diffractometer (XRD) indicate that there are
only two phases in the coating. The images of scanning electron microscope (SEM) show that TiB2 is unevenly
distributed in Al2O3 matrix from the microscopic view, which causes loss of interfacial polarization and con­
ductivity. This work illustrates the broad prospects of TiB2-based materials in high-temperature microwave
absorption applications.

1. Introduction resistance and wave absorption. In addition, the microwave absorption


should remain stable when the temperature changes [9].
With the rapid development of information technology and the A variety of materials have been considered, including metal oxides,
increasingly complex battlefield environment, the appearance of stealth carbon-based materials and ceramics, such as Si3N4, SiCf/SiC, TiC, WC,
weapons has an important impact on modern war mode [1–4]. Due to MnO2, ZnO, Ti3SiC2, carbon fibers, CNTs, and graphene [10–27].
the significance of improving survival and penetration ability, radar However, the key problems that seriously limits its further wide appli­
stealth technology has been paid more and more attention. At present, in cation still exist. For instance, high temperature absorbing material
order to achieve the purpose of radar stealth, there are mainly two made of SiCf/SiC–Al2O3 composites [20] has a thickness of up to 3 mm,
methods, including shape stealth technology and material stealth tech­ which can increase the weight of the workpiece for the excessive
nology [5]. The former generally reduces the radar cross section (RCS) thickness. High-temperature microwave-absorption property of
of the target within a certain range of incident angles by changing the Ti3SiC2/NASICON [15] coating changes greatly with the change of
shape. The latter uses radar absorbing materials (RAMs) to convert temperature from 25 ◦ C to 500 ◦ C. Its bandwidth of RL below -5 dB
electromagnetic wave energy into heat energy and then dissipate it. almost covered the X-band with a thickness of 1.8 mm at 200 ◦ C.
Excessive shape design will affect the aerodynamic performance of the However, it is all greater than -5 dB at 500 ◦ C. To sum up, many key
aircraft. Therefore, it is necessary to utilize RAMs to achieve better problems remain exist, including excessive thickness, relatively narrow
stealth capability. At the same time, modern aircraft needs to maintain absorption frequency range, and decreasing electromagnetic wave ab­
stealth mode in the process of flexible high-speed maneuver in order to sorption efficiency with increasing temperature.
complete challenging tasks. Due to aerodynamic heat, the surface tem­ Radar absorbing coatings (RACs) has been widely studied due to its
perature of aircrafts rises rapidly with the increase of flight speed [6–8]. excellent properties, including strong adhesion, simple preparation
RAMs used in such environment must have both high temperature process and high temperature oxidation resistance. Generally, RACs are

* Corresponding author.
** Corresponding author.
E-mail addresses: mahuar@xjtu.edu.cn (H. Ma), wangjun563@163.com (J. Wang).

https://doi.org/10.1016/j.ceramint.2021.03.047
Received 16 January 2021; Received in revised form 23 February 2021; Accepted 3 March 2021
Available online 13 March 2021
0272-8842/© 2021 Elsevier Ltd and Techna Group S.r.l. All rights reserved.
S. Zhao et al. Ceramics International 47 (2021) 17337–17344

composed of dielectric absorbents dispersed in insulating matrix, weight ratios, and then put into a cylinder mill containing zirconia balls
including WC/Al2O3, Ti3SiC2/cordierite, TiO2/Al2O3, and LaSrMnO3/ and alcohol where they were ball milled for 18 h at a rotary speed of 320
Al2O3 [28–32]. It is believed that the EM absorption of a specific ma­ rpm. Then, using polyvinyl alcohol (PVA) as binder, the slurry was
terial is determined by its complex permittivity. By adjusting the pro­ spray-dried by spray granulation technology to ensure that the powder
portion of each component, suitable EM parameters can be obtained to particles become spherical. There are several key steps that affect the
acquire better impedance matching in thin thickness. Thus, the coating quality of the powder. The first is the composition of the slurry listed in
can properly match the EM impedance and consume more incident EM the support information (SI). Furthermore, the main parameters of spray
energy. drying include temperature, slurry flow rate, nozzle speed, atomization
Because the problems of thickness and thermal stability have not air flow rate, etc., which also has a key influence on powder quality, as
been solved, it is necessary to find a new type of RAC with excellent shown in SI. In the second step, through APS technique, the new type of
high-temperature microwave absorption and ultra-thin thickness. Tita­ RAC was prepared on the surface of nickel-based superalloy, which is a
nium diboride (TiB2) [33,34], the most stable compound of boron and commonly used high temperature structural material for its high ther­
titanium, has already been widely used in cermet coatings, and has mal stability and anti-corrosion properties. The process parameters of
many excellent physical and chemical properties, such as high melting APS are shown in the SI.
point (3253 K), extremely low density (4.52 g/cm3), extremely high
hardness (34 GPa) and excellent corrosion resistance. Due to its excel­
lent electrical conductivity [35], it is suitable for microwave absorption 2.2. Characterization methods
as dielectric absorbents dispersed in insulating matrix. Alumina (Al2O3)
is a widely used substrate material for RACs due to its thermal properties The phase structure of the coating was detected by X-ray diffrac­
and exceptional mechanical characteristics. These properties make these tometer (Philips X-Pert Pro-Diffractometer, Almelo, The Netherlands).
two substances suitable for designing new RAC. In addition, the microstructure of spherical powder and coating was
In this study, TiB2 and Al2O3 were used as raw materials to prepare carefully observed by scanning electron microscope (SEM, model JSM-
new RAC by APS technique. Fig. 1 illustrates the main design scheme. To 6360, JEOL, Tokyo, Japan). Then, four samples with different compo­
obtain excellent absorbing performance, suitable EM parameters were sition ratios with dimension of 22.86 × 10.16 × 1.2 mm were measured
obtained by adjusting the content of TiB2 in the composite. The dielec­ with the X-band waveguide (8.2–12.4 GHz) to obtain the EM scattering
tric and EM wave absorption properties of TiB2/Al2O3 coatings at parameter (S parameter) of the fabricated samples, respectively. By
different temperatures were studied and discussed in detail. Then, the further calculating the S parameter, the complex permittivity can be
optimal component ratio was selected through simulations and experi­ obtained. According to the transmission line theory, the thickness-
ments. Furthermore, the influence of the TiB2 content on the absorption dependent RLs of the designed RACs were calculated. Finally, the RL
performance of the coating was explained from the microscopic point of of the prepared RACs with a dimension of 180 mm × 180 mm × 1.4 mm
view. Our work shows that the RAC possesses good wave absorption was measured at 25–800 ◦ C by using the arch reflection test system.
performance in a wide temperature range with a thin thickness, which
illustrates a bright prospect of this material system in high temperature 3. Results and discussion
applications.
Fig. 2(a) shows the morphology of composite feedstock powders
2. Methods fabricated by spray granulation technology under SEM. As shown in the
image, the particle shape is spheroid or spherical, and its diameter
2.1. Preparation of the TiB2/Al2O3 coatings via plasma spraying mostly between 35 to 60 μm. There is no combination between them,
technology which indicates that the powder has excellent fluidity. These charac­
teristics make it an ideal choice for coating preparation by APS
Commercially available titanium diboride and alumina high-purity technique.
powder (purity > 99.9%) were selected as raw materials and provided Fig. 2(b) shows the 2000-fold and 16000-fold sectional SEM images
by Jiaxing Tiantan Materials Co., Ltd. China. The APS is used to produce of the RAC respectively. From the 2000-fold sectional SEM images, it is
x.wt TiB2~(1-x).wt Al2O3 coating (x = 0.15, 0.20, 0.25, 0.30). The main observed that the prepared coating exhibits an evident lamellar struc­
procedure includes the following two specific steps: preparing spherical ture, which is a typical feature of plasma sprayed coatings. Besides, it
powder and spraying samples in turn. In the first step, in order to pre­ possesses relatively low porosity and high density, as shown in SI. The
pare nearly spherical powder with excellent fluidity for plasma spraying, distribution of TiB2 in Al2O3 matrix is uniform macroscopically due to
TiB2 and Al2O3 powders were mixed with the above four different the reason that TiB2 in Al2O3 being fully mixed in the ball mill. However,
from the microscopic view, as shown in the 16000-fold sectional SEM

Fig. 1. Schematic diagram of a candidate absorbing coating through conductance material and dielectric material.

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Fig. 2. (a) Micro morphology of composite feedstock powders by spray granulation technology. (b) Cross sectional SEM images of the radar absorption coatings. (c)
XRD patterns of the 30%.wt TiB2~70%.wt Al2O3 coating at different temperature.

image below, the regions of TiB2 are formed in different sizes and polarization ability of materials in EM field. Debye relaxation theory
shapes. The inhomogeneous microscopic configuration does not affect [36] gives the relationship between the complex permittivity and tem­
the uniform distribution of TiB2 in Al2O3 matrix from a macroscopic perature. Moreover, the conductivity is also an important factor
view. affecting the complex permittivity for the electric loss absorbing mate­
Fig. 2(c) shows XRD pattern of the 30%.wt TiB2 ~ 70%.wt Al2O3 rial [37]. Therefore, the influence of temperature on complex permit­
coating when temperature increases from 25 ◦ C to 800 ◦ C. Obviously, tivity of the absorbing coating is mainly determined by relaxation
only TiB2 and Al2O3 phases can be observed. They are stable with the polarization and the change of high temperature conductivity. Accord­
increasing temperature, which indicates that TiB2 does not react with ing to Debye’s theory [36], the relationship between relaxation polari­
Al2O3 and has strong oxidation resistance at elevated temperature. Be­ zation time, ε, and ε′′ can be expressed as follows:
sides, this shows that TiB2 does not oxidize when the coating is prepared
τ(T) = τ0 exp(Ea / KT) (1)
at high temperature. All these characteristics are vital to the EM ab­
sorption performance. εs − ε∞
(2)

Fig. 3 shows the complex permittivity (ε = ε′ − jε′′ ) and the dielectric ε = ε∞ +


1 + ω2 τ 2
loss (tanδ) of 30%.wt TiB2–70%.wt Al2O3 coating at different tempera­
tures from 25 ◦ C to 800 ◦ C. The ε′ , ε′′ and tanδ all increases as the εs − ε∞ σ (T)
ε′′ = ⋅ωτ(T) + (3)
temperature rises. Specifically, as the temperature rises from 25 ◦ C to 1 + ω2 τ2 (T) ε0 ω
800 ◦ C, the values of the three parameters at 10 GHz increase from 23.57
to 30.38, from 3.23 to 9.63, and from 0.137 to 0.327 respectively. The Where τ0, K and Ea represent specific relaxation time, Boltzmann con­
values of the other three coatings are illustrated in SI. stant and activation energy respectively; ε∞ and εs represent the limited
The complex permittivity is an important parameter reflecting the high-frequency permittivity and the limited low-frequency (static)
permittivity, respectively. As shown in Eqs. (1) and (2), τ(T) is

Fig. 3. (a) (b) (c) Permittivity of 30 %wt.TiB2 – 70 %wt.Al2O3 coating at various temperature in x band; (d)Variations of conductivities of x.wtTiB2 – (1-x)wt.Al2O3
coatings at various temperature.

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negatively correlated with temperature, which then leads to the rise of 1.4 mm exhibits good electromagnetic absorption performance at
ε’. Meanwhile, at high frequency, ωτ ≫ 1, Eq. (1) can be simplified as 800 ◦ C. In this case, RL bandwidths below -5 dB and -10 dB can reach
follows: almost the whole x band and 1.52 GHz respectively. For further
research, the effective absorption bandwidth (EAB) was defined as the
εs − ε∞ σ(T)
ε′′ = + (4) frequency bandwidth when RL is below -10 dB. Besides, when EAB value
ωτ(T) ε0 ω
reaches maximum value, the corresponding thickness is regarded as the
The value of the first item increases with elevated temperature. Be­ optimum thickness (dm).
sides, the value of the second item is determined by the temperature- Furthermore, in order to study the EM absorbing performance of the
dependent conductivity, namely σ (T). The electrical conductivity of coating, we obtained the dm and relevant data via detailed comparison
the coating mainly results from the electronic caused by the addition of and analysis, when EBA reached its maximum at 800 ◦ C, as shown in
TiB2. Therefore, according to the electronic conduction theory, the σ (T) Fig. 4(b). As x is 0.15, the coating exhibit nearly no absorbing property,
of the coatings can be described as follows: which will not be discussed here. When x is 0.2, 0.25 and 0.3, dm is 2.1
mm, 1.6 mm and 1.4 mm, respectively. As shown in Fig. 4(c), the quarter
σ (T) = Ae− U/kT
(5) wavelength (λ1/4) is calculated according to following formula [38]. Due
to the frequency dispersion of the permittivity, λ1/4 decreases monoto­
Where A is constant and U is the potential barrier. Evidently, the σ (T)
nously for each coating as the frequency varies from 8.2 to 12.4 GHz.
increases with temperature. As shown in Fig. 3(d), the experimental
Noted that dm of the three coatings is slightly different from the λ1/4 at
results also confirm the theoretical prediction. Hence, as shown in the
the fm. This is mainly due to the frequency dispersion of the complex
previous analysis, ε’’ will also increase with increase of temperature.
permittivity.
Fig. 4 contains a reflection loss (RL) graph based on calculated
values. Following formulas are used to calculate the data of the four d=
c
√̅̅̅ (10)
coatings [11]: 4f ε

Zin (n) − Z(0) According to the transmission line theory [39], the total electric field
R= (6) intensity reaches the maximum at the λ1/4 above the metal plane. When
Zin (n) + Z(0)
x is 0.3, the electric field distribution of the coating at 8.2, 9.53 and 11.2
√̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅
μ 2πfd√̅̅̅̅̅ GHz are presented, as shown in Fig. 5. EM power absorbed in the coating
Zin (1) = Z(0) tanh(j με) (7) is mainly determined by loss as well as the electric field strength, which
ε c
is described as follows [38]:
RL = 20 log|R| (8)
Pabs ∝ωε′′ |E|2 (11)
c
fm = √̅̅̅̅̅ (9) where E is the total electric field in the medium. It can be clearly seen
4d με
from the figure that when the EM frequency is 8.2 and 12.4 GHz, d is less
Where Zin, f, d and c represent normalized input impedance, EM fre­ than and greater than its corresponding λ1/4, respectively, and the total
quency, thickness and speed of light in vacuum of the coating, respec­ electric field does not reach the maximum. When f is 9.53 GHz, the
tively. fm stands for the frequency when the RL is the smallest. It can be incident EM power absorbed by the coating is strongest at λ1/4 because
seen clearly from the above equation that thickness is an important of the maximum total electric field.
parameter closely related to RL and fm. The action mechanism is as In addition, we also calculated the normalized complex EM imped­
follows. The characteristic impedance (Zm) of the specific material is ance (Z) and only the coating (x = 0.3) was discussed here, as shown in
determined by its electromagnetic parameters. However, Zin is deter­ Fig. 6(a). The values of other two coatings are expressed in SI. It can be
mined not only by its characteristic impedance, but also its thickness. seen from the calculation results that the real part (Z’) and imaginary
When the d of the coating changes, the Zin of the coating will also part (Z’’) of impedance are close to 1 and 0, respectively, indicating that
change, so that the impedance matching of the EM wave between the the coating possesses a well EM absorbing performance in X-band.
coating with different thickness and free space (Z0 = 377 Ω) will change. Particularly at 9.53 GHz, the RL of the coating reaches its minimum
When the thickness is too large or too small, the impedance mismatch value.
causes the incident EM not to enter the coating. For an appropriate Fig. 6(b) shows the correlation between RL and the temperature of
coating thickness, the incident EM can enter the coating and then be the 30%.wtTiB2 – 70%.wtAl2O3 coating with thickness of dm. The results
effectively consumed and absorbed. indicate that fm decreases with the increase of temperature, but EAB
For instance, as shown in Fig. 4(a), fm moves to low frequency as rises. More specifically, as the temperature rises from temperature 25 ◦ C
d becomes thicker. It is worth noting that the coating with a thickness of to 800 ◦ C, the value of fm decreases from 11.78 to 9.53 GHz, and the EAB
value increases from over 0.71 to 1.52 GHz. From the above

Fig. 4. (a) The RL of 30%.wtTiB2 – 70%.wtAl2O3 coating at various thickness in X-band; (b) The best EM absorbing performance of x.wtTiB2 – (1-x)wt.Al2O3 coatings
at 800 ◦ C; (c) The calculated quarter wavelength of each coating at their best absorption performance.

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Fig. 5. Electric field distributions of the 1.4-mm-thick 30 %wt.TiB2–70 %wt.Al2O3 coating in the 800 ◦ C at (a) 8.2 GHz, (b) 9.53 GHz and (b) 12.4 GHz.

Fig. 6. (a) The impedance Z of coating with x = 0.3 at 1.4 mm in 800 ◦ C; (b) The correlation between temperature and RL of coating; (c) Real part of Z as a function
of the temperature for coating under 25–800 ◦ C. (d) Imaginary part of Z as a function of the temperature for coating under 25–800 ◦ C.

information, it can be observed that ε’ and ε’’ gradually increase with earlier, shows that the two materials will not react at high temperature,
the increase of temperature, which also decreases the value of fm. For which is crucial for EM absorption. In the design, TiB2 is dispersed in
ideal impedance matching, Z’ approach to 1 and Z’’ approach to 0. As Al2O3 as an absorbent with high ε’ and ε’’. The combination of these two
show in Fig. 6(c) and (d), with the increase of temperature, Z’ is closer to materials creates a new effective medium with excellent absorption
1 and Z’’ is decreasing toward 0. It can be observed that when the performance. Therefore, no chemical reaction between them is what the
temperature rises from 400 ◦ C to 800 ◦ C, the value of Z’ and Z’’ does not design hoped for. Secondly, as shown in Fig. 2 (b), the distribution of
change much, which indicates Zin and Z0 can match well in a wide TiB2 in Al2O3 is not uniform which leads to localized conductance
temperature range. In addition, as described above, as temperature connection in different regions and causes interfacial polarization, as
elevating, the value of tanδ also increases. Accordingly, more incident shown in Fig. 7 (a). On a macro scale, this shows an increase of the
electromagnetic waves can come in the coating and then be consumed, permittivity, then achieves good impedance matching [40] in the
which demonstrates that EAB will be widen with the increase of tem­ designed thickness, which allows more EM waves enter the interior of
perature. The results of other two coatings are illustrated in SI. the coating to be consumed.
In this prepared coating, 30% content of TiB2 is moderate to obtain There are three cases when Al2O3 and TiB2 are combined, as shown
the appropriate EM parameters and deduce to the well performed in Fig. 7 (b), (c) and (d). First, the percentage of Al2O3 is too high, and
impedance matching. From a micro point of view, adding proper TiB2 TiB2 is unevenly distributed in the former. Therefore, the properties of
will increase the conductive loss of the coating. In conclusion, the EM each microscopic region are determined by the dominant Al2O3, and the
absorption performance of the coating mainly depends on its micro­ resistivity between regions is relatively high. Therefore, there is almost
structure. Firstly, the XRD pattern of variable temperature, mentioned no interface polarization loss, and the triggered conduction loss is also

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Fig. 7. (a) Micro mechanism diagram of electromagnetic absorption of TiB2/Al2O3 Composite Coating; (b) (c) (d) the composition of three different contents of
TiB2/Al2O3.

very small. Second, the ratio of the two is moderate, as shown in Fig. 7 reducing the thickness of the coating can improve the bonding strength
(c). In this case, the conductivity of TiB2 cannot be negligible. At the between the parts and prevent tiny cracks between layers, thus
same time, due to its uneven distribution in Al2O3 matrix, there are improving thermal shock resistance [43,44]. This will significantly
localized conductance connections with different shapes and sizes in the prolong the service life of the coating in high temperature applications.
mesoscopic or microscopic regions. Therefore, the sample will generate Therefore, it would be meaningless to pursue only electromagnetic ab­
various electric polarization, as well as interface polarization, which will sorption performance and ignore the consideration of coating thickness.
lead to energy loss of incident EM wave. Third, when TiB2 content In practical application, when the thickness is required to be as thin as
reaches a certain level, the conductive particles contact each other to possible, RL < -5 dB is usually set as the expected target. Therefore,
form a conductive network [41], which leads to a rapid increase in when x = 0.3, the composite coating with a thickness of 1.4 mm is the
conductivity and complex permittivity. This can cause an impedance most suitable coating for practical application. Its thickness is not only
mismatch between the coating and air [37,42]. When EM waves incident extremely thin, but also the whole X-band’s RL is below -5 dB at 800 ◦ C.
to the surface of the material, more of them are reflected away, resulting In order to verify the theoretical RL value at elevated temperature, a
in a weak absorption performance. For TiB2/Al2O3 composite coating, prototype (x = 0.3) was manufactured by APS, as shown in Fig. 8(a).
by adjusting the content of TiB2 and Al2O3, the coating with excellent Then it was heated to 800 ◦ C to measure reflectivity. Fig. 8 (b) exhibits
high-temperature absorbing properties can be obtained. the comparison between calculated and the measured RL values when
Considering the high temperature application environment, the coating thickness is only 1.4 mm at 800 ◦ C. It can be observed that

Fig. 8. (a) The fabricated sample; (b) A comparison between experimental and simulated result; (c) Measured absorption spectra for the fabricated sample versus
temperature.

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