Ultrablack coating could make next-gen telescopes even better

Sometimes, seeing clearly requires complete black. For astronomy and precision optics, coating devices in black paint can cut down on stray light, enhancing images and boosting performance. For the most advanced telescopes and optical systems, every little bit matters, so their manufacturers seek out the blackest blacks to coat them.

In the Journal of Vacuum Science & Technology A, by AIP Publishing, researchers from the University of Shanghai for Science and Technology and the Chinese Academy of Sciences developed an ultrablack thin-film coating for aerospace-grade magnesium alloys.

Their coating absorbs 99.3% of light while being durable enough to survive in harsh conditions.

For telescopes operating in the vacuum of space, or optical equipment in extreme environments, existing coatings are often insufficient.

"Existing black coatings like vertically aligned carbon nanotubes or black silicon are limited by fragility," said author Yunzhen Cao.

"It is also difficult for many other coating methods to apply coatings inside a tube or on other complicated structures. This is important for their application in optical devices as they often have significant curvature or intricate shapes."

To solve these problems, the researchers turned to atomic layer deposition (ALD). With this vacuum-based manufacturing technique, the target is placed in a vacuum chamber and sequentially exposed to specific types of gas, which adhere to the object's surface in thin layers.

"One big advantage of the ALD method lies in its excellent step-coverage ability, which means we can obtain uniform film coverage on very complex surfaces, such as cylinders, pillars, and trenches," said Cao.

To make their ultrablack coating, the team used alternating layers of aluminum-doped titanium carbide (TiAlC) and silicon nitride (SiO2). The two materials work together to prevent nearly all light from reflecting off the coated surface.

"TiAlC acted as an absorbing layer, and SiO2 was employed to create an anti-reflection structure," said Cao.

"As a result, nearly all of the incident light is trapped in the multilayer film, achieving efficient light absorption."

In tests, the team found an average absorption of 99.3% across a wide range of light wavelengths, from violet light at 400 nanometers all the way to near infrared at 1,000 nanometers.

Using a special barrier layer, they even applied their coating to magnesium alloys, which are often used in aerospace applications but are easily corroded.

"What's more, the film shows superb stability in adverse environments, and is tough enough to withstand friction, heat, damp conditions, and extreme temperature changes," said Cao.

The authors hope their coating will be used to enhance space telescopes and optical hardware operating in the most extreme conditions and are working to further improve its performance.

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Backyard insect inspires invisibility devices, next gen tech

Leafhoppers, a common backyard insect, secrete and coat themselves in tiny mysterious particles that could provide both the inspiration and the instructions for next-generation technology, according to a new study led by Penn State researchers. In a first, the team precisely replicated the complex geometry of these particles, called brochosomes, and elucidated a better understanding of how they absorb both visible and ultraviolet light.

This could allow the development of bioinspired optical materials with possible applications ranging from invisible cloaking devices to coatings to more efficiently harvest solar energy, said Tak-Sing Wong, professor of mechanical engineering and biomedical engineering. Wong led the study, which was published today (March 18) in the Proceedings of the National Academy of Sciences of the United States of America (PNAS).

The unique, tiny particles have an unusual soccer ball-like geometry with cavities, and their exact purpose for the insects has been something of a mystery to scientists since the 1950s. In 2017, Wong led the Penn State research team that was the first to create a basic, synthetic version of brochosomes in an effort to better understand their function.

"This discovery could be very useful for technological innovation," said Lin Wang, postdoctoral scholar in mechanical engineering and the lead author of the study. "With a new strategy to regulate light reflection on a surface, we might be able to hide the thermal signatures of humans or machines. Perhaps someday people could develop a thermal invisibility cloak based on the tricks used by leafhoppers. Our work shows how understanding nature can help us develop modern technologies."

Wang went on to explain that even though scientists have known about brochosome particles for three-quarters of a century, making them in a lab has been a challenge due to the complexity of the particle's geometry.

"It has been unclear why the leafhoppers produce particles with such complex structures," Wang said, "We managed to make these brochosomes using a high-tech 3D-printing method in the lab. We found that these lab-made particles can reduce light reflection by up to 94%. This is a big discovery because it's the first time we've seen nature do something like this, where it controls light in such a specific way using hollow particles."

Theories on why leafhoppers coat themselves with a brochosome armor have ranged from keeping them free of contaminants and water to a superhero-like invisibility cloak. However, a new understanding of their geometry raises a strong possibility that its main purpose could be the cloak to avoid predators, according to Tak-Sing Wong, professor of mechanical engineering and biomedical engineering and corresponding author of the study.

The researchers have found that the size of the holes in the brochosome that give it a hollow, soccer ball-like appearance is extremely important. The size is consistent across leafhopper species, no matter the size of the insect's body. The brochosomes are roughly 600 nanometers in diameter -- about half the size of a single bacterium -- and the brochosome pores are around 200 nanometers.

"That makes us ask a question," Wong said. "Why this consistency? What is the secret of having brochosomes of about 600 nanometers with about 200-nanometer pores? Does that serve some purpose?"

The researchers found the unique design of brochosomes serves a dual purpose -- absorbing ultraviolet (UV) light, which reduces visibility to predators with UV vision, such as birds and reptiles, and scattering visible light, creating an anti-reflective shield against potential threats. The size of the holes is perfect for absorbing light at the ultraviolet frequency.

This potentially could lead to a variety of applications for humans using synthetic brochosomes, such as more efficient solar energy harvesting systems, coatings that protect pharmaceuticals from light-induced damage, advanced sunscreens for better skin protection against sun damage and even cloaking devices, researchers said. To test this, the team first had to make synthetic brochosomes, a major challenge in and of itself.

In their 2017 study, the researchers mimicked some features of brochosomes, particularly the dimples and their distribution, using synthetic materials. This allowed them to begin understanding the optical properties. However, they were only able to make something that looked like brochosomes, not an exact replica.

"This is the first time we are able to make the exact geometry of the natural brochosome," Wong said, explaining that the researchers were able to create scaled synthetic replicas of the brochosome structures by using advanced 3D-printing technology.

They printed a scaled-up version that was 20,000 nanometers in size, or roughly one-fifth the diameter of a human hair. The researchers precisely replicated the shape and morphology, as well as the number and placement of pores using 3D printing, to produce still-small faux brochosomes that were large enough to characterize optically.

They used a Micro-Fourier transform infrared (FTIR) spectrometer to examine how the brochosomes interacted with infrared light of different wavelengths, helping the researchers understand how the structures manipulate the light.

Next, the researchers said they plan to improve the synthetic brochosome fabrication to enable production at a scale closer to the size of natural brochosomes. They will also explore additional applications for synthetic brochosomes, such as information encryption, where brochosome-like structures could be used as part of an encryption system where data is only visible under certain light wavelengths.

Wang noted that their brochosome work demonstrates the value of a biomimetic research approach, where scientists looks to nature for inspiration.

"Nature has been a good teacher for scientists to develop novel advanced materials," Wang said. "In this study, we have just focused on one insect species, but there are many more amazing insects out there that are waiting for material scientists to study, and they may be able to help us solve various engineering problems. They are not just bugs; they are inspirations."

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Next-generation batteries could go organic, cobalt-free for long-lasting power

In the switch to "greener" energy sources, the demand for rechargeable lithium-ion batteries is surging. However, their cathodes typically contain cobalt -- a metal whose extraction has high environmental and societal costs. Now, researchers in ACS Central Science report evaluating an earth-abundant, carbon-based cathode material that could replace cobalt and other scarce and toxic metals without sacrificing lithium-ion battery performance.

Today, lithium-ion batteries power everything from cell phones to laptops to electric vehicles.

One of the limiting factors for realizing a global shift to energy produced by renewable sources -- particularly for the transition from gasoline-powered cars to electric vehicles -- is the scarcity and mining difficulty of the metals, such as cobalt, nickel and magnesium, used in rechargeable battery cathode manufacturing.

Previous researchers have developed cathodes from more abundant and lower cost carbon-containing materials, including organosulfur and carbonyl compounds, but those prototypes couldn't match the energy output and stability of traditional lithium-ion batteries.

So, Mircea Dincǎ and his colleagues wanted to see if other carbon-based cathode materials could be more successful.

They may have found a worthy candidate in bis-tetraaminobenzoquinone (TAQ). TAQ molecules form layered solid-state structures than can potentially compete with traditional cobalt-based cathode performance.

Building on their prior work that showed TAQ's effectiveness as a supercapacitor material, Dincǎ's team tested the compound in a cathode for lithium-ion batteries. To improve cycling stability and to increase TAQ adhesion to the cathode's stainless-steel current collector, they added cellulose- and rubber-containing materials to the TAQ cathode. In the researchers' proof-of-concept demonstration, the new composite cathode cycled safely more than 2,000 times, delivered an energy density higher than most cobalt-based cathodes and charged-discharged in as little as six minutes. The TAQ-based cathodes need additional testing before they appear on the market, but the researchers are optimistic that they could enable the high-energy, long-lasting and fast-charging batteries needed to help speed a global transition to a renewable energy future that's cobalt- and nickel-free.

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