Material Application of a Transformer Box: A Study on the Electromagnetic Shielding Characteristics of Al–Ta Coating Film with Plasma-Spray Process

In this study we present the results of two experiments. In the first one, a Ta–Al–SS (stainless steel (SS)) multilayer coating structure was prepared using plasma spraying equipment to investigate the coating structure and interface properties. In the second one, Ta–Al on multilayer glass was prepared using the sputtering process to measure the thickness effect of thin film on electromagnetic wave shielding (EMI) characteristics and on the design of high-power switchboard covers. According to the experimental results, the multilayer structure of Ta–Al on SS improves the mechanical properties of a stainless steel plate by enhancing the explosion-proof property. An appropriate thickness of the plasma-sprayed pure aluminum layer can increase the adhesion to the stainless steel substrate and buffer the stress effect. After heat treatment (annealing), the Ta–Al–SS multilayer structural characteristics are excellent and suitable for shielding effects at different temperatures and humidity, which can be used as a reference for the engineering application of communication rooms and base power stations. According to EMI test of multi-coated glass (Ta–Al–glass), by increasing the thickness of Ta layer, we cannot effectively improve full-frequency EMI shielding with improved shielding at low-mid frequency condition. In addition, the Ta–Al interface formation of an Al–Ta–O compound layer can improve the adiabatic effect to reduce the thermal conductivity.