Highly stable anti-reflection and anti-dust hard silica coating with controlled mechanical and optical properties for harsh desert environment applications

This study addresses a critical issue faced in harsh desert environments characterized by intense sunlight and dusty conditions, which pose significant challenges for applications ranging from solar panels and optical devices to architectural surfaces. In response, we have developed a silica coating that may offer a solution to these environmental challenges. The silica coating exhibits excellent anti-reflective properties, drastically reducing the amount of sunlight reflected from the coated surface and thereby enhancing photon absorption. This study examines the controlled tuning of optical and morphological properties in silica thin films, fabricated through reactive RF magnetron sputtering of an SiO₂ target, using various oxygen-to-argon flow ratios [r(O₂)=O₂/Ar]. Empirical properties of the coatings were systematically examined and demonstrated to be finely tunable by adjusting r(O₂). Additionally, surface morphology, as assessed by average roughness (Ra) measurements, was found to be strongly influenced by the oxygen concentration during deposition. Hydrophilicity of the silica coatings was assessed using contact angle measurements, demonstrating that the oxygen content in the films plays a significant role in influencing their hydrophilic properties. Furthermore, micromechanical properties of these silica coatings right after sputtering deposition and those exposed to outdoor conditions were systematically evaluated using Vickers indentation, showing, on one hand, that the hardness of the silica coatings can be regulated by adjusting the oxygen levels introduced during the deposition process, and on the other hand, a high mechanical stability of these silica even after 24 months of outdoor exposure in desert environments. Finally, this study also highlights that dust accumulation on the surface of these silica coatings is inversely proportional to the oxygen content into the films, demonstrating the coatings’ self-cleaning properties. The hydrophobicity of the deposited silica thin films further contributes to their self-cleaning capabilities, making them particularly valuable in enhancing the performance of photovoltaic modules, especially in desert environments where dust accumulation can significantly impact efficiency. This multifaceted approach not only improves optical and mechanical properties but also offers a sustainable solution for maintaining the efficiency of solar panels and other devices in challenging environmental conditions.