Tailoring Cold Spray Powder and Spray Process Parameters to Produce a Novel Radar Absorbing Coatings with Enhanced Mechanical Properties

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MASc Candidate Yomna Elsahli, yelsahli@uottawa.ca, University of Ottawa; PhD Candidate Hamid Rahmati, hrahmati@uottawa.ca, University of Ottawa; Assistant Professor Aleksandra Nastic, anastic@uottawa.ca, University of Ottawa; Part Time Professor / Research Associate Mohammed Yandouzi, yandouzi@uottawa.ca, University of Ottawa; BASc Candidate Ali Sherry, asher076@uottawa.ca, University of Ottawa; Prof. Bertrand Jodoin, bertrand.jodoin@uottawa.ca, University of Ottawa; 

Radar absorbing technologies are essential for reducing the detectability of military assets, where maintaining a low radar cross-section is vital for operational advantage. Common radar-absorbing materials include carbon-based coatings/paints, polymers, ferrite tiles and foam-based radar-absorbing materials (RAM). Each material is tuned for specific radar frequency bands, and the effectiveness depends on thickness, angle of incidence, and operating environment. These solutions generally suffer from poor mechanical properties, require frequent maintenance and are sometimes considered as hazardous materials. Furthermore, new advanced radar technologies are being developed to operate in the THz regime, specifically for hypersonic asset detection. To overcome these issues, it is proposed to develop novel radar absorbing coatings with enhanced mechanical properties able to operate in the THz regime. Copper is used as a model material, and a powder production method is developed and tailored to result in optimal powder geometry maximizing resonance for radar-absorption over a large frequency band. Additionally, a high-frequency electromagnetic numerical model is developed and used to demonstrate the shielding capabilities of the manufactured powder. To achieve wideband frequency absorption, cold spray (CS) was selected as coating process due to its potential to preserve the complex internal geometry of the feedstock, which is an essential requirement for maximizing electromagnetic resonance.

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Erscheinungsdatum

March 2026

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