Effect of Ball-Milling Process on Microwave Absorption Behaviors of Flaky Carbonyl Iron Powders

Electromagnetic (EM) wave absorption performance is greatly affected by the microscopic morphology of the absorbing material particles. In this study, a facile and efficient ball-milling method was applied to increase the aspect ratio of particles and prepare flaky carbonyl iron powders (F-CIPs), one of the most readily commercially available absorbing materials. The effect of ball-milling time and rotation speed on the absorption behaviors of the F-CIPs was investigated. The microstructures and compositions of the F-CIPs were determined using scanning electron microscopy (SEM) and X-ray diffraction (XRD). The EM parameters were measured using a vector network analyzer (VNA) in the frequency range of 2–18 GHz. The results indicated that the ball-milled flaky CIPs exhibited a better absorption ability than the raw spherical CIPs. Among all the samples, the sample milled at 200 r/min for 12 h and the sample milled at 300 r/min for 8 h showed remarkable EM parameters. The ball-milling sample with 50 wt.% F-CIPs had a minimum reflection loss peak of −14.04 dB at a thickness of 2 mm and a maximum bandwidth (RL < −7 dB) of 8.43 GHz at a thickness of 2.5 mm, a result that conformed with the transmission line theory. Hence, the ball-milled flaky CIPs were considered to be beneficial for microwave absorption.