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Large scale manufacturing route to metamaterial coatings using thermal spray techniques and their response to solar radiation.

Faisal, Nadimul Haque; Sellami, Nazmi; Venturi, Federico; Hussain, Tanvir; Mallick, Tapas; Muhammad-Sukki, Firdaus; Bishop, Alex; Upadhyaya, Hari; Katiyar, Nirmal Kumar; Goel, Saurav


Federico Venturi

Tanvir Hussain

Tapas Mallick

Firdaus Muhammad-Sukki

Alex Bishop

Hari Upadhyaya

Nirmal Kumar Katiyar

Saurav Goel


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 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 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, Cr2O3 and TiO2 were deposited onto various substrates (e.g., steel, aluminium, glass, indium tin oxide (ITO) coated glass) with a fine wire mesh (143 ┬Ám 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 nm to 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 the electromagnetic wave propagation. Comparison between Cr2O3 and TiO2 coatings on aluminium substrates showed reduced three orders of reduced reflectance for Cr2O3 coatings (for 1 mm aperture size) throughout the spectrum. It was concluded that for a similar bandgap, Cr2O3 coatings on aluminium substrate will yield improved optical performance than TiO2 coating, and hence more useful to fabricate opto-electronic devices.


FAISAL, N.H., SELLAMI, N., VENTURI, F., HUSSAIN, T., MALLICK, T., MUHAMMAD-SUKKI, F., BISHOP, A., UPADHYAYA, H., KATIYAR, N.K. and GOEL, S. [2021]. Large scale manufacturing route to metamaterial coatings using thermal spray techniques and their response to solar radiation. Emergent materials [online], Online First. Available from:

Journal Article Type Article
Acceptance Date Jun 18, 2021
Online Publication Date Jul 4, 2021
Deposit Date Jun 21, 2021
Publicly Available Date Jul 5, 2022
Journal Emergent materials
Print ISSN 2522-5731
Electronic ISSN 2522-574X
Publisher Springer
Peer Reviewed Peer Reviewed
Keywords Electromagnetic wave; Optical properties; Thermal spray coatings; APS; S-HVOF; Solar radiation
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