NOVATEUR PUBLICATIONS

International Journal of Research Publications in Engineering and Technology [IJRPET]

ISSN: 2454-7875
VOLUME 3, ISSUE 6, Jun.-2017
CHARACTERIZATION AND COMPARISON OF SOLAR SELECTIVE
COATINGS BETWEEN NI-AL AND NI-CO ON ALUMINUM SUBSTRATE
AVINASH M. WAGHMARE
PG Scholar, Department of mechanical engineering, JSPM’S RSCOE, Tathawade, Pune, Savitribai Phule Pune University,
India.

DR. J. A. HOLE
Prof. Department of Mechanical Engineering JSMP’S RSCOE, Tathawade, Pune, Savitribai Phule Pune University, India

ABSTRACT: water heater system. In order to have efficient solar water

An ideal solar absorber surface coating must heater system, solar selective coatings must have good
have good optical properties like high solar spectral properties. An Ideal solar selective coating have
absorptance with minimum solar emittance. very high absorptance coefficient over wavelength range of
Development of new coating is fabricated by solar radiations and nearer to infrared range (spectrum
embedding metallic particles composed of a nickel- from 0.3µm to 2.0µm) and very low emittance coefficient
aluminium (NiAl) alloy into the black paint as well as for long wavelength radiations (spectrum from 2.0µm to
solar selective black nickel-cobalt (NiCo) 20µm). Although black coating materials have high solar
electroplating on aluminium alloys with nickel absorptance, they also suffer from the high infrared
undercoat is done. Characterization of such solar emissivity. Generally, solar selective coatings frequently
selective surface coatings are done and compared applied in combinations of different materials. For example,
with commercial black paint. A new and affordable materials having high solar absorptivity are blended with
solar selective surface coating having higher solar materials having low emissitivity as an underlayler coating.
absorption efficiency with low in-frared emittance There exists a few solar selective paints with good efficiency
compared to the commercial black paint coating used such as Solokte (solec, USA), Solarect-Z (Slovenia) and
in most ordinary solar water heating systems has Thurmalox ([Link]). Most of these paints have to be
been developed. Characterization of coating includes brought from their original modifiers and can not be used
Optical properties studies of coatings, Surface by the many people around the world due to their high
morphology and XRD studies, and solar water heater import and tax costs. Other alternatives materials are
performance with new coatings. studied such as black cobalt, black nickel – cobalt, black
KEYWORDS: Solar absorptance, solar emittance, solar copper-nickel alloys, black nickel and copper-magnesium
selective coatings, NiAl, NiCo surface morphology, films (Ehab AlShamaileh, 2010).
XRD. Scanning electron microscopic studies showed that
the particles in the coatings are of dentritic structure. The
1. INTRODUCTION: high degree of solar absorptance is related to the
Easy and efficient way to utilize solar energy is the irregular dentritic structure and surface roughness of the
direct conversion of sun rays to thermal energy (heat) for coatings ([Link], et al, 2007).
various applications such as solar cookers, air Solar selective black chrome coatings are widely
conditioning, water pumping and water heating. Due to used for decorative as well as functional applications
affordable cost of solar water heating system, it can be because of their durability and excellent optical
used by many households in the Middle East. In this region properties. Though black chrome coatings provide
average daily solar radiation is around 5.5 Kw.h/m2and excellent properties, the use of toxic hexavalent
around 300 days in a year are sunny. Many researchers chromium and requirement of high current densities are
have focused on how to improve already existing solar the major drawbacks in producing these coatings (J.K.
water heating system by minimizing the thermal loss by Dennis, et al, 2003).
providing the insulating material around the storage tank. Several alternatives to black chrome plating like
Also, by providing the better solar selective coating on the black nickel, black nickel–cobalt, black brass, and black
solar collector surface efficiency can be improved with cobalt have been studied by several investigators ([Link],
some previous research. The recent study on solar water et al, 1997), (N. Karuppiah, et al, 2000), (Purnima
heater shows that, the materials which are having good Richharia, 1996), (Enrique Viveros, 1998). Recently,
thermal conductivity like copper, aluminium or stainless metallic and non-metallic nanoparticles have been
steel when used for tubing purpose in solar water heaters applied in solar- energy applications by the researchers
act as a weak absorber for solar radiations. So, solar like absorbing films consisting of nickel nanoparticles
selective coatings are necessary to get best results in solar embedded in dielectric matrix of alumina Al2O3
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 NOVATEUR PUBLICATIONS
International Journal of Research Publications in Engineering and Technology [IJRPET]
ISSN: 2454-7875
VOLUME 3, ISSUE 6, Jun.-2017
(Bostrom T, et al, 2008). Carbon nano-particles in NiO, powder is blended with black paint (modified paint) in
ZnO, SiO matrices (Katumba, G, et al, 2008). But these various percentages of compositions has a paint layer
selective coatings have not been experimentally tested thickness of 10µm on aluminium plate.
on solar heaters. The surface morphology of black
nickel, black nickel-cobalt coatings and its relationship
with optical properties have been studied on zincated
substrates (N.C. Mehra, et al ,1989).

2. MODIFIED/NEW SOLAR SELECTIVE COATINGS:

NiAl coating on Al substrate. Individually, nickel
and aluminium have interesting thermal and spectral
selective properties. Also, nickel shows good corrosion
resistance and when nickel particles are added to other
coating materials it will improve their heat resistance and
durability. Nickel exhibits high solar absorptivity.
Aluminium has high reflectivity in the infrared region of
the spectrum from 0.3µm to 2.0µm which exhibits low Fig.2 Photograph of Paint Mixer
thermal emissions produced by infrared radiant emission
from the collector to the ambient air. Therefore, it makes In below, Table 1. Shows different compositions
a lot of sense to try a new coating formula based on NiAl. made of the coatings to be tested.
a) REQUIREMENTS OF MATERIALS: Table 1: Different compositions for samples
Sample Black-paint % Ni-Al % Acetone (ml)
Black paint (cellulose nitrate resin, Duco), Acetone
(Duco), nickel–aluminium alloy (50:50, Vineeth Precious 1 100 0 50
Catalysts [Link]), hydrochloric acid, sodium chloride and 2 97 3 50
two solar water heaters. 3 94 6 50
4 91 9 50

Sample No.1 Sample No.2

Sample No.3 Sample No.4

Fig.1 Photograph of required material. Fig.3 Photograph of Samples of NiAl coating.

b) NIAL COATING PROCESS: c) OUTDOOR EXPERIMENT:

An electric mixer shown in fig [Link] used to mix the paint An experiment is conducted on five 15mm aluminium
with the Ni-Al particles to produce homogeneous mixture tubes filled with stationary water and fitted with a
of coating. A coating mixture produced by various thermometer to compare the different compositions’
percentages of NiAl alloy particles and the black paint. absorbance to sunlight. The first tube was painted with
This mixture is then diluted with acetone of 50 ml in order commercial black paint and the other three were painted
to have uniform layer of paint with the help of brush with the various compositions of the modified paint
painting on base metal of aluminium (alloy 6061). The shown in Table 1 (samples 2–4). The temperature was
painted layer of black paint (unmodified) and NiAl alloy monitored over a period of 1 day. The preliminary results

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 NOVATEUR PUBLICATIONS
International Journal of Research Publications in Engineering and Technology [IJRPET]
ISSN: 2454-7875
VOLUME 3, ISSUE 6, Jun.-2017
of testing shows that, as the Ni-Al% by mass in black
paint increases, the solar heat absorbance also increases.
By visual inspection of prepared sample, it is seen that
there is no any facial crack on samples to be
[Link] is no any visual defects present in the
[Link], out of samples 2, 3 and 4, the optimum
composition of 6% Ni-Al by mass is selected for further
testing of solar water heater system. The performance
study of solar water heater is done by degreasing the
aluminium pipes used in solar water heater by using
acetone and further tubes are etched with help of diluted
hydrochloric acid (HCL) followed by washing of tubes Table 3 Observations for flat plate collector in April-2016.
with pure water. The sand paper in fine grit is also used Time Inlet water Temp. In Temp. In
for good paint adherence treatment on tubes. After this temperature collector with collector
sequence of operations, aluminium tubes are painted to in 0C Unmodified with
give thin uniform homogeneous layer by brush painting. 0
Paint ( C) Modified
Painted tubes are left to dry in air for 48 hours away 8.00 A.M 20 31.5 (0C)
Paint31.5
from dust. A photograph of the experimental setup is 10.00 A.M 20 37.5 39.0
shown in Fig. 4. It consists of two identical simple SWHSs 12.00 Noon 20 42.5 46.0
where each is made of a flat plate collector and a storage 2.00 P.M 20 44.0 48.0
tank. 4.00 P.M 20 43.5 47.0
6.00 P.M 20 40.0 41.0
7.00 P.M 20 31.5 32.0

Performance evaluation of solar flat plate collector can

be done by calculating efficiency, which can be calculated
by,
ɳ = Useful Heat Gain (Qw) / Heat supplied (Qs) (1)
Amount of useful heat gain can be calculated by
considering water temperature at the inlet and outlet of
tubes, and taking into account the water flow rate and its
specific heat,
Qw = m × Cp × ΔT (2)
Total heat supplied to the collector is depends upon solar
intensity (It) and collector area (Ac) is given by,
QS = It × Ac (3)
Table 4 Efficiency of flat plate collector in May-2016.
Time Inlet water Efficiency in % of Efficiency in
Fig.4 A Photograph of Experimental Setup temperature in collector with % of
All temperature measurements are done by using 0C unmodified paint collector
mercury-filled thermometers. The probes were immersed (ᵒC) with
modified
inside the tubes and sealed at the inlets and the outlets of
paint (ᵒC)
the collectors. The temperature inside and outside of 7.00 A.M 23 6.2 6.2
tubes and the ambient air temperature are measured. All 8.00 A.M 23 6.2 6.5
temperatures are recorded every hour from sunshine to 10.00 A.M 23 30.383 31.21
sunset (e.g. 8 am to 7 pm in the summer). The 12.00 Noon 23 333
61.80 63.27
measurements were carried out regularly from May 2016 2.00 P.M 23 77.52 83.80
and April 2016. 3.00 P.M 23 78.57 85
4.00 P.M 23 76.47 81.71
Observations for flat plate collector in May 2016 and
6.00 P.M 23 37.71 38.76
April 2016 are given in below table.
7.00 P.M 23 19.90 20.53
Table 2 Observations for flat plate collector in May-2016.

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International Journal of Research Publications in Engineering and Technology [IJRPET]
ISSN: 2454-7875
VOLUME 3, ISSUE 6, Jun.-2017
Table 5 Efficiency of flat plate collector in April-2016 iii) Chemical polishing in a solution containing
Time Inlet water Efficiency in % of Efficiency in orthophosphoric acid 80%, nitric acid 3.5% and copper
temperature in collector with % of
0.01% for 20–25 s at 90 1C followed by hot water rinse.
0C unmodified paint collector
(ᵒC) with iv) De-smutting in an acid solution containing 10 ml/L
modified sulfuric acid, 12 ml/L hydrofluoric acid and 25 ml/L nitric
paint (ᵒC) acid for 2–3 min at room temperature followed by water
8.00 A.M 20 24 24
rinsing and air drying.
10.00 A.M 20 36.66 39.80
v) Nickel plating using watts bath.
12.00 Noon 20 47.14 54.47
2.00 P.M 20 50.28 58.66
vi) Black nickel cobalt plating in a solution containing
4.00 P.M 20 49.23 56.57 cobalt sulphate, nickel sulphate, ammonium acetate and
6.00 P.M 20 41.90 44.00 sodium thiocyanate at 28–30ᵒC.
7.00 P.M 20 24.09 25.14 c) IMAGES OF ELECTROPLATING OF BLACK NI-CO ON
ALUMINIUM ALLOY 6061:
d) LABORATORY MEASUREMENTS:
i) Surface morphological studies for the different
coating samples of NiAl (10µm) carried out with
scanning electron microscope (SEM) on SPPU-JEOL .
ii) X-ray diffraction (XRD) patterns of the NiAl coatings are
obtained by SPPU-JEOL .
NiCo coating on Al substrate. Sample No.1 Sample No.2
a) REQUIRED MATERIALS: Fig.5 Photograph of Samples of black Ni-Co.
Aluminium alloy 6061 (Al-97.9, Mg-1.0, Si-0.6, Cu-
0.25, Cr-0.25%) specimens of the size 100×50×2mm d) LABORATORY MEASUREMENTS
are processed for black nickel–cobalt plating at Nexus i) Surface morphological studies were carried out with
Engineers ([Link]) chikkali, Pune. scanning electron microscope SPPU-JEOL.
b) NICO COATING PROCESS: ii) X-ray diffraction (XRD) patterns of the coatings were
As per the following sequence of operations: obtained by Philips SPPU-JEOL.
i) Solvent degreasing in trichloroethylene using iii) UV-VIS Spectrophotometer used for absorbance and
ultrasonic bath for 5–10 min at room temperature. Transmission Studies of NiCo samples conducted in
ii) Alkaline cleaning in a solution containing sodium Shivaji University, Kolhapur.
carbonate 20–25 g/L, sodium meta silicate 8–12 g/L and
tri sodium orthophosphate, at 65ºC for 3–4 min followed 3. RESULT AND DISCUSSIONS:
by water rinsing. FOR NIAL COATING
a) SURFACE MORPHOLOGY (SEM) AND XRD STUDIES:
Below fig.6 represents micrographs of surface of the
black paint shown in fig. (a) And the Ni-Al alloy modified
coating on aluminium surface shown in fig. (b).For the SEM
testing component size of 5mm×5mm is required for both
paint. The uniform dispersion of the Ni-Al particles is a
major factor in the enhancement of the solar absorptivity
and the reduction of thermal losses.
Fig.6a) Micrographs of surface of the black paint. X-ray diffraction (XRD) pattern of black paint coating on
aluminum sample is shown in fig.7. Testing of XRD is done
on a specimen size of 1mm×1mm at Department of Physics,
in SPPU.

Fig.6b) Micrographs Ni-Al modified coating on Al substrate

Fig.7 XRD pattern of black paint coated sample.

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International Journal of Research Publications in Engineering and Technology [IJRPET]
ISSN: 2454-7875
VOLUME 3, ISSUE 6, Jun.-2017
X-ray diffraction (XRD) pattern of Ni-Al coating on 90
aluminum sample is shown in fig.8, clears that the 80
modified coating contains Ni and Al with no oxide 70
detected. 60
50
Fig.8 XRD pattern of Ni-Al coated samples. 40
30 unmodified paint

b) SOLAR COLLECTOR TEMPERATURE AND 20 modified paint

10
EFFICIENCY STUDIES: 0
From below fig.9&10, it is clear that the NiAl-modified
7 8 10 12 2 3 4 6 7
paint always gave higher temperature for the water inside
the collector compared to commercial black paint.

70 Fig.10Efficiency vs time grap for modified and unmodified

paint on solar collector in May-2016 & April-2016.
60 FOR NICO COATING
50 A) EFFECT OF NICKEL UNDERCOAT THICKNESS ON
OPTICAL PROPERTIES OF BLACK NI–CO COATINGS
Tempreture (⁰C)

40
100
30 80
20 60
Unmodified Paint 40
10 unmodified
Modified Paint 20 paint
0 0
11:00 AM
7:00 AM
8:00 AM
9:00 AM
10:00 AM

12 NOON
1:00 PM
2:00 PM
3:00 PM
4:00 PM
5:00 PM
6:00 PM
7:00 PM

7 8 10 12 2 3 4 6 7

Time of the Day in hours

.
8
60
6
50
4
Temperature ( ⁰C)

40 2
30 0
20
10 Unmodified Paint 0 5 10 15
Modified Paint Undercoat Thickness in µm
0

Fig.11 Effect of under coat thickness on the optical

properties (ratio of absorptivity to the emissivity).
Time of the Day in hours
Fig.9 Temperature curve for modified and unmodified Fig.11. shows that the influence of the thickness of
paint on solar collector in May-2016 & April-2016 nickel undercoat on the optical properties of the black
nickel cobalt(NiCo)coatings.
80 The nickel undercoat thickness was varied from 2.5
60 to 10 µm. Lower nickel undercoat thickness resulted in a
gray colored black nickel cobalt coating with low
40 unmodified paint
absorptance to emittance ratio. At 5.0–7.5 µm undercoat
modified paint
20 thickness a good black Ni–Co coating with high
absorptance to emittance ratio (5.57) is obtained on UV-
0 VIS Spectrophotometer at shivaji university, Kolhapur.
8 10 12 2 4 6 7 Further there will decrease in absorptance to emittance
ratio with increase in undercoat thickness.

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International Journal of Research Publications in Engineering and Technology [IJRPET]
ISSN: 2454-7875
VOLUME 3, ISSUE 6, Jun.-2017
ii) Surface morphology and XRD studies XRD pattern in Fig.13 shows the presence of FCC
structure with major intensity Ni (1 1 1) peak and very
small intensity Ni–Co peaks.

4. CONCLUSIONS
This paper concludes,
1) The new coating, comprising NiAl alloy particles, shows
that the solar water heater system collect thermal energy
more efficiently than ordinary black paint.
Fig.12 Micrographs of black nickel cobalt coating on
2) An outdoor experimental study of flat plate collector
nickel plated aluminum alloy 6061.
shows that, the new system having NiAl coating always
produce warmer water.
[Link] the surface morphology of black nickel–
3) Black nickel cobalt electroplating on aluminium alloys
cobalt coatings on nickel-plated aluminum substrates.
process provides high solar absorptance (0.95) and low
Surface morphology of the coatings affects the solar
thermal emittance (0.10), which is suitable for solar
absorptance of the coatings. The enhancement of solar
selective applications.
absorptance may occur either by an array of fine particles
4) SEM and XRD studies showed that, the particles in the
causing intrinsic adsorption or by reducing the front
coatings are of dentritic structure. The high degree of solar
surface reflections from an absorber surface. The particles
absorptance is related to the irregular dentritic structure
have irregular needle like shape shown in fig.12, also the
and surface roughness of the coatings with no oxides
grains are compact, have more uniform structure in
present which help to increase corrosion resistance.
nickel-plated substrate. The irregular and needle like
5) Characterizations done in this paper shows that, NiAl
structure facilitates trapping of radiation so that the solar
and NiCo coatings have more efficient than ordinary black
energy is absorbed by the black coating to a greater extent.
paint used in solar water heating systems.
X-ray diffraction (XRD) is a powerful non-
destructive technique for characterizing crystalline
5. REFERENCES
materials. It provides information on crystal structure,
1) Ehab AlShamaileh, Department of Chemistry, Faculty of
phase, preferred crystal orientation (texture), and other
Science, the University of Jordan, Amman 11942, Jordan
structural parameters, such as average grain size,
Solar Energy 84 (2010), 1637-1643, Testing of a new
crystallinity, strain, and crystal defects.
solar coating for solar water heating applications.
The peak intensities are determined by the distribution of
2) [Link], [Link], [Link], thermal
atoms within the lattice. Consequently, the X-ray
system group, ISRO Satellite Centre, Banglore, India.
diffraction pattern is the fingerprint of the periodic atomic
3) Solar Energy Materials Solar& cells 91(2007), 629-635
arrangements in a given material. XRD pattern of the black
Solar selective black nickel-cobalt coatings on aluminum
nickel cobalt coating (25–50 nm) with nickel undercoat is
alloys.
given in fig.13.
4) J.K. Dennis (2003), T.E. Such, Nickel and Chromium
X-ray diffraction (XRD) is a versatile, non-
Plating, third ed., Woodhead Publishing Ltd.,
destructive analytical technique that reveals detailed
Cambridge, UK, p 240.
information about the chemical composition,
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crystallographic structure and physical properties of
6) N. Karuppiah, S. John, Bull(2000). Electrochem. 16 (2)
materials. X-ray diffraction peaks are produced by
71. Purnima Richharia(1996), Thin Solid Films 272, 7.
constructive interference of a monochromatic beam of X-
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rays diffracted at specific angles from each set of lattice
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8) Bostrom T., Wackelgard, E., Westin, G.,(2008). Solution-
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9) Katumba, G., Makiwa, G., Baisitse, T.R., Olumekor, L.,
Forbes, A., Wackelgard, E., (2008). Solar selective
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Fig.13 XRD pattern of black nickel cobalt coating. 11) C. Siva Kumar, S.M. Mayanna, K.N. Mahendra, A.K.

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International Journal of Research Publications in Engineering and Technology [IJRPET]
ISSN: 2454-7875
VOLUME 3, ISSUE 6, Jun.-2017
Sharma,
12) R. Uma Rani, Appl. Surf. Sci. 151, 280.
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