Atmosphere Plasma-Sprayed Carbon Nanotubes/Cordierite Nanocomposite Coatings for Microwave Absorption Applications

Multi-walled carbon nanotubes (MWCNTs)/cordierite (MAS) nanocomposite coatings with different MWCNT contents were prepared via atmosphere plasma spraying method. The characteristics of the MWCNTs/MAS powders and as-sprayed coatings, such as microstructure and phase constitution, were observed and measured. The dielectric properties and microwave absorption properties of MWCNTs/MAS powders and nanocomposite coatings have been investigated at the frequency of 8.2-12.4 GHz with different MWCNT contents and sample thicknesses. When the MWCNT content increased to 7%, the nanocomposite coating revealed the highest dielectric constant and optimal microwave absorption property. Further increase in MWCNT content led to severe oxidation of MWCNTs during the plasma spray process, which resulted in lower dielectric constants and poor microwave absorption property. Moreover, the sample thickness has a noticeable influence on the reflection loss (RL) of the MWCNTs/MAS coatings, and the coating of 2.4-mm thickness shows optical microwave absorption with a minimum RL of −15.61 dB and bandwidth of 2.35 GHz.