Stealth Technology Using Barium Hexaferrite and Ultrafine Copper Powder in Coatings
Since 2008, intensive research has been carried out with various additives in different combinations to develop paints that can give their metallic substrates a radar-absorbing camouflage coating. In 2022, a very interesting test using barium hexaferrite and ultrafine copper powder in combination was published, showing that the material absorbed about one-third of incident radar waves. In 2023, sales of ultrafine copper powder suddenly quadrupled compared to the previous year.
The Technology
Polymer composites have become an integral part of modern life due to their light weight, ease of processing, and exceptional combination of properties. They are now found in aerospace, aviation, and even defense industries. In this context, the use of polymer composites for radar absorption applications has been discussed.
Radar is a detection system that uses electromagnetic waves to determine information such as the distance, altitude, direction, or speed of objects. It can detect both moving objects such as aircraft, ships, and vehicles, and stationary ones such as terrain. Radar can also be used to gather meteorological data. This technology, which revolutionized air and naval warfare, is one of the most important technological developments of World War II. In fact, the term RADAR was coined in 1940 by the U.S. Navy as an acronym for RAdio Detection And Ranging. Since then, it has gained importance not only for military and police use but also for flight navigation and weather observation.
At first glance, radar operation seems simple: a signal is emitted, it bounces off an object, and the reflected signal is received. This is similar to how an echo works—but instead of sound, radar uses microwaves. The degree of reflection and refraction depends on the properties and surface of the material hit by the signal. When a radar signal strikes a perfectly flat surface, it is reflected in one direction. When it hits an uneven surface, it is scattered in multiple directions, and only a small portion of the original signal returns to the receiver. Another way to reduce the reflected signal is through absorption of the radar waves by the material itself.
Radar-absorbing materials (RAM) have a mechanism that traps incoming radar waves within the material, preventing them from being reflected. The earliest forms of such materials were developed by the Germans during World War II.
Barium hexaferrite and ultrafine copper powder were used to produce radar-absorbing composite coatings. The barium hexaferrite powders were synthesized using the sol-gel method. After synthesis, mixtures were prepared by adding barium hexaferrite and ultrafine copper powder in various amounts to a polyurethane resin (to determine the dependence on concentration). These mixtures were then applied to glass and metal substrates, producing coatings about 3 mm thick, which were dried at room temperature in air.
The morphology of barium hexaferrite shows smooth-edged, plate-like particles with an average particle size of about 5 μm. The copper particles are relatively large, between 7–10 μm.
The radar absorption of the sample containing 5% barium hexaferrite and 10% copper powder reached a maximum of 11.38%, while increasing the copper content further boosted absorption beyond 12%. Theoretically, maximum absorption could exceed 80%.
As for the mechanism of copper, copper itself does not absorb electromagnetic waves. The radar absorption mechanism in copper differs slightly from that in barium hexaferrite. When electromagnetic waves strike the copper surface, the electric field drives free electrons, generating an alternating current. These oscillating electrons create a magnetic alternating field in and around the conductor. This generates an electromagnetic counterforce that confines the charge carriers to the surface of the conductor. Thus, the electromagnetic waves are either absorbed by the electrons or reflected in the same direction, with some of the electromagnetic energy dissipated as heat.
Analysis of the results shows that coatings reinforced with barium ferrite and copper powder exhibit higher magnetic saturation values than single-component coatings. As the amounts of barium hexaferrite and copper increase, radar absorption also increases. The addition of barium hexaferrite and copper therefore creates a synergistic effect, enhancing absorption performance. This synergy arises because the additives contribute independently through their magnetic and electrical properties—each activating different mechanisms that together improve radar absorption.
The Copper Powder Market
Copper powder is primarily produced in Russia, Canada, and Chile. In Canada and Chile, mostly biologically derived, nearly spherical copper powder is made, often used in pharmaceutical applications. In Russia, nearly all copper powder production is for technological uses.
With the (hot) war Russia began against Ukraine in 2022, global trade patterns changed dramatically. Western banks now rarely process payments related to Russian goods. As a result, thousands of Russian companies restructured—relocating operations, moving machinery abroad, or restarting under new names in neighboring countries. Consequently, we now see copper powder producers operating along the Russian border, from Estonia to Kazakhstan.
Because most producers of ultrafine metallic powders are our clients, we are in a good position to monitor the market for ultrafine copper powder. We have seen increasingly large volumes traded. In 2018, global trade was estimated at around 20 tonnes. By 2023, we alone observed over 60 tonnes changing hands, suggesting a current annual market volume of roughly 100 tonnes.
Since demand in other known application areas of copper powder has not grown nearly as much in the past five years, we suspect the emergence of a new player — the military. Known applications for copper powder include: electronics, semiconductors, antibacterial coatings, 3D printing, pharmaceuticals, and paint production.
For the military, the potential applications are virtually limitless. From satellites to armored vehicles, anything could be made invisible to modern radar systems. Such a tactical advantage could be worth billions of U.S. dollars to the world’s militaries.
We will continue to monitor this market and report again.
ISE AG, Institut für seltene Erden und Metalle AG, Kanada, Militär, Die bekannten Anwendungsgebiete von Kupferpulver, 3-D Druck, Copper powder, Chile, elektrischen strom, Elektronik, Pharmalogie, Lack, Halbleiter, Elektromagnetische Wellen, Antibakterielle beschichtung, Radar, Schiffe, Ultrafeinen Kupferpulver, US-Marine, ultrafeinen, Verteidigungsindustrie, Wechslestrom, Zweiten Weltkrieg
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