Lightweight nickel foam coated with multi-walled carbon nanotubes for enhanced electromagnetic interference shielding: experimental and multiphysics evaluation
Source abstract
Abstract
Abstract This study presents the development and performance evaluation of a lightweight, multi-layered electromagnetic interference (EMI) shielding material composed of open-cell nickel (Ni) foam integrated with multi-walled carbon nanotubes (MWCNTs). While previous works have investigated CNTs or metallic foams separately, a systematic analysis combining dip-coated CNTs on Ni foams with Multiphysics simulations remains scarce. Addressing this gap, the Ni foam (100 PPI) was coated with MWCNTs at two concentrations (16 mg/mL and 20 mg/mL) using a dip-coating method in polyvinyl alcohol. Samples were tested over 800–3,000 MHz. The 20 mg/mL CNT-coated sample (F1) exhibited the highest shielding effectiveness (SE) of 48.165 dB, outperforming the uncoated and 16 mg/mL samples. COMSOL Multiphysics simulations confirmed and extended the experimental findings, validating the effectiveness of the porous Ni-CNT structure in attenuating electromagnetic waves through reflection, absorption, and scattering. The study bridges the experimental-simulation gap and identifies CNT concentration as a critical design parameter for scalable EMI shielding solutions.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Electromagnetic wave absorption materials · Electromagnetic Fields and Biological Effects · Advanced Antenna and Metasurface Technologies
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
Department of Mechanical Engineering , SR University , Warangal , Telangana , India
Department of Machining, Assembly and Engineering Metrology, Faculty of Mechanical Engineering , VSB-Technical University of Ostrava , 70800 , Ostrava , Czech Republic
Department of Mechanical Engineering , Indian Institute of Technology Kanpur , Kalyanpur, 208016 , Kanpur , Uttar Pradesh , India
Department of Mechanical Engineering, School of Engineering, Faculty of Science, Technology & Architecture , Manipal University Jaipur , 303007 , Jaipur , Rajasthan, India
References (29)
Show source-provided references
1. Stansberry, K, Anderson, J, Rainie, L. The internet will continue to make life better. Pew Res Cent 2019:1–29.
2. Yuvarani, A, Latha, R. Cell phone tower: a gift or curse. Int J Sci Res 2013;2:70–3.
3. Team TACS. Radiofrequency (RF) radiation. Am Cancer Soc 2022:1–11.
4. Premlal, PD, Eldhose, NV. Electromagnetic shielding solutions for cell tower radiation exposure. Int J Creat Res Thoughts 2020;8.
5. Zhang, Y, Wang, Z, Zhang, B, Zhou, C, Zhao, G-L, Jiang, J, et al.. Morphology and electromagnetic interference shielding effects of SiC coated carbon short fibers. J Mater Chem C 2015;3:9684–94. https://doi.org/10.1039/c5tc01987g.10.1039/C5TC01987G ↗
6. Duan, J, Wang, X, Li, Y, Liu, Z. Effect of double-layer composite absorbing coating on shielding effectiveness of electromagnetic shielding fabric. Mater Res Express 2019;6:086109. https://doi.org/10.1088/2053-1591/ab1d2d.10.1088/2053-1591/ab1d2d ↗
7. Kondawar, SB, Modak, PR. Theory of EMI shielding. In: Materials for Potential EMI Shielding Applications. Amsterdam, The Netherlands: Elsevier Inc.; 2020:9–25 pp.10.1016/B978-0-12-817590-3.00002-6 ↗
8. Munalli, D, Dimitrakis, G, Chronopoulos, D, Greedy, S, Long, A. Electromagnetic shielding effectiveness of carbon fibre reinforced composites. Compos Part B Eng 2019;173:106906. https://doi.org/10.1016/j.compositesb.2019.106906.10.1016/j.compositesb.2019.106906 ↗
9. Li, T-T, Wang, X, Wang, Y, Shiu, B-C, Peng, H-K, Liu, L, et al.. Fe3O4 and Ag micro/nano coating for high-efficiency flame retardancy and electromagnetic interference shielding. Prog Org Coating 2023;181:107563. https://doi.org/10.1016/j.porgcoat.2023.107563.10.1016/j.porgcoat.2023.107563 ↗
10. Ebneth, H, Fitzky, HG. Plastic parts with a good electromagnetic shielding effect in the high frequency range. Mater Des 1983;4:828–32. https://doi.org/10.1016/0261-3069(83)90183-8.10.1016/0261-3069(83)90183-8 ↗
11. Ji, K, Zhao, H, Zhang, J, Chen, J, Dai, Z. Fabrication and electromagnetic interference shielding performance of open-cell foam of a Cu-Ni alloy integrated with CNTs. Appl Surf Sci 2014;311:351–6. https://doi.org/10.1016/j.apsusc.2014.05.067.10.1016/j.apsusc.2014.05.067 ↗
12. Khomenko, V, Butenko, O, Chernysh, O, Barsukov, V, Suchea, MP, Koudoumas, E. Electromagnetic shielding of composite films based on graphite, graphitized carbon black and iron-oxide. Coatings 2022;12:665. https://doi.org/10.3390/coatings12050665.10.3390/coatings12050665 ↗
13. Maruthi, N, Faisal, M, Raghavendra, N. Conducting polymer based composites as efficient EMI shielding materials: a comprehensive review and future prospects. Synth Met 2021;272:116664. https://doi.org/10.1016/j.synthmet.2020.116664.10.1016/j.synthmet.2020.116664 ↗
14. Wang, R, He, F, Wan, Y, Qi, Y. Preparation and characterization of a kind of magnetic carbon fibers used as electromagnetic shielding materials. J Alloys Compd 2012;514:35–9. https://doi.org/10.1016/j.jallcom.2011.10.061.10.1016/j.jallcom.2011.10.061 ↗
15. Satish Kumar, K, Rengaraj, R, Venkatakrishnan, GR, Chandramohan, A. Polymeric materials for electromagnetic shielding – a review. Mater Today Proc 2021;47:4925–8.10.1016/j.matpr.2021.03.720 ↗
16. Yang, Y, Gupta, MC, Dudley, KL. Towards cost-efficient EMI shielding materials using carbon nanostructure-based nanocomposites. Nanotechnology 2007;18:345701. https://doi.org/10.1088/0957-4484/18/34/345701.10.1088/0957-4484/18/34/345701 ↗
17. Xu, L, Jia, L-C, Yan, D-X, Ren, P-G, Xu, J-Z, Li, Z-M. Efficient electromagnetic interference shielding of lightweight carbon nanotube/polyethylene composites via compression molding plus salt-leaching. RSC Adv 2018;8:8849–55. https://doi.org/10.1039/c7ra13453c.10.1039/C7RA13453C ↗
18. Chao, Z, Yu, Y, Lei, F, Hu, D. A lightweight and flexible CNT/Fe3O4 composite with high electromagnetic interference shielding performance. Carbon Lett 2021;31:93–7. https://doi.org/10.1007/s42823-020-00152-y.10.1007/s42823-020-00152-y ↗
19. Faisal, NH, Ahmed, R, Sellami, N, Prathuru, A, Njuguna, J, Venturi, F, et al.. Thermal spray coatings for electromagnetic wave absorption and interference shielding: a review and future challenges. Adv Eng Mater 2022;24:2200171. https://doi.org/10.1002/adem.202200171.10.1002/adem.202200171 ↗
20. Antunes, M. Recent trends in polymeric foams and porous structures for electromagnetic interference shielding applications. Polymers 2024;16:195. https://doi.org/10.3390/polym16020195.10.3390/polym16020195 ↗
21. Varela, JY, Jurado, LG, Armendáriz, IO, Pérez, CA, González, CC. The role of multi-walled carbon nanotubes in enhancing the hydrolysis and thermal stability of PLA. Sci Rep 2024;14:8405. https://doi.org/10.1038/s41598-024-58755-8.10.1038/s41598-024-58755-8 ↗
22. He, W, Wang, S, Zhang, H, Fang, L, Wan, Y. Lightweight multifunctional poly (dimethylsiloxane)/hollow microsphere/carbon nanotube composite foam for electromagnetic interference shielding and thermal management. ACS Appl Polym Mater 2025;7:10293–303. https://doi.org/10.1021/acsapm.5c02302.10.1021/acsapm.5c02302 ↗
23. Kozak, N, Matzui, L, Vovchenko, L, Kosyanchuk, L, Oliynyk, V, Antonenko, O, et al.. Influence of coordination complexes of transition metals on EMI-shielding properties and permeability of polymer blend/carbon nanotube/nickel composites. Compos Sci Technol 2020;200:108420. https://doi.org/10.1016/j.compscitech.2020.108420.10.1016/j.compscitech.2020.108420 ↗
24. Ji, K, Zhao, H, Zhang, J, Chen, J, Dai, Z. Fabrication and electromagnetic interference shielding performance of open-cell foam of a Cu-Ni alloy integrated with CNTs. Appl Surf Sci 2014;311:351–6. https://doi.org/10.1016/j.apsusc.2014.05.067.10.1016/j.apsusc.2014.05.067 ↗
25. Stoica, ȘD, Nicolaescu, I, Moise, AM. Electromagnetic coupling analysis in printed circuit boards: a comparative study using MATLAB and Ansys HFSS simulations. J Mil Technol 2024;7:43–8. https://doi.org/10.32754/jmt.2024.1.06.10.32754/JMT.2024.1.06 ↗
26. Singh, BP, Saini, K, Choundhary, V, Teotia, S, Pande, S, Saini, P, et al.. Effect of length of carbon nanotubes on electromagnetic interference shielding and mechanical properties of their reinforced epoxy composites. J Nanosci Nanotechnol 2014;16:2161.10.1007/s11051-013-2161-9 ↗
27. Lan, C, Zou, L, Wang, N, Qiu, Y, Ma, Y. Multi-reflection-enhanced electromagnetic interference shielding performance of conductive nanocomposite coatings on fabrics. J Colloid Interface Sci 2021;590:467–75. https://doi.org/10.1016/j.jcis.2021.01.074.10.1016/j.jcis.2021.01.074 ↗
28. Bashir, T, Ali, A, Persson, NK, Ramamoorthy, SK, Skrifvars, M. Recent advances in electromagnetic interference shielding properties of carbon-fibre-reinforced polymer composites – a topical review. J Mater Sci Mater Electron 2021;32:26799–820.10.1007/s10854-021-06900-8 ↗
29. Zhang, Z, Cheng, L, Sheng, T, Yu, J, Tan, J, Yang, W. SiC nanofiber-coated carbon/carbon composite for electromagnetic interference shielding. ACS Appl Nano Mater 2022;5:195–204. https://doi.org/10.1021/acsanm.1c02544.10.1021/acsanm.1c02544 ↗