Flexible carbon-coated FeNi alloy/PDMS nanocomposites toward a multifunctional high-performance electromagnetic absorber

The increasing prevalence of electromagnetic wave technology has raised concerns regarding electromagnetic pollution and its potential hazards. Microwave absorbing materials (MAMs) have emerged as an effective solution for capturing and dissipating electromagnetic waves. This study presents a novel approach for developing flexible microwave absorbers by dispersing carbon-coated FeNi alloy nanoparticles (FeNi@C NPs) into a polydimethylsiloxane (PDMS) matrix. The unique contributions lie in the mass production of (FeNi)@C NPs through the arc plasma and controlled making of (FeNi)@C/PDMS nanocomposites for practical electromagnetic wave (EMW) absorption/shielding application. Simultaneously, the formation mechanism of (FeNi)@C NPs is illustrated in detail by real-time optical emission spectroscopy. The obtained (FeNi)@C/PDMS nanocomposites show multifunctionality such as hydrophobicity and mechanical performance, rendering them suitable for applications in lightweight flexible electronics, wearable devices, and stealth technology. Through adjustments in the contents of (FeNi)@C fillers, the (FeNi)@C/PDMS nanocomposites exhibit excellent microwave absorption capacity. At a mass ratio of 15% of (FeNi)@C NPs, the minimum reflection loss is -33.51 dB at a thickness of 2.3 mm with an effective absorption band of 4.96 GHz. This enhanced performance is attributed to the synergistic effects of magnetic and dielectric loss, multiple reflection/scattering, conduction loss, and suitable impedance matching. Furthermore, the (FeNi)@C/PDMS nanocomposites demonstrate remarkable corrosion resistance, exhibiting a positive shift in corrosion potential to -0.18 V compared to bare aluminum (-0.83 V), along with a corresponding protection efficiency of 98.78%. In conclusion, this study provides a validated strategy for the fabrication of EMW absorption nanocomposites consisting of magnetic nanoparticle fillers and polymer matrix, highlighting their potential for application in intricate environments.