Fabrication and electromagnetic characteristics of electromagnetic wave absorbing sandwich structures

The radar absorbing structures (RAS) having sandwich structures in the X-band (8.2–12.4 GHz) frequencies were designed and fabricated. We added conductive fillers such as carbon black and multi-walled carbon nanotube (MWNT) to composite prepregs and polyurethane foams so as to efficiently increase the absorbing capacity of RAS. In order to improve the mechanical stiffness of RAS, we adopted the sandwich structures made of composite face sheets and foam cores. Glass fabric/epoxy composites containing conductive carbon black and carbon fabric/epoxy composites were used for the face sheets. Polyurethane foams containing MWNT were used as the core material. Their permittivity in the X-band was measured using the transmission line technique. The reflection loss characteristics for multi-layered sandwich structures were calculated using the theory of transmission and reflection in a multi-layered medium. Three kinds of specimens were fabricated and their reflection losses in the X-band were measured using the free space technique. Experimental results were in good agreement with simulated ones in 10-dB absorbing bandwidth.     

EM characteristics of the RAS composed of E-glass/epoxy composite and single dipole FSS element

From the methods to reduce radar cross section (RCS) such as shaping of the target, radar absorbing material (RAM), and radar absorbing structure (RAS), the RAS composed of frequency selective surface (FSS) screens and low-loss composite materials is used widely because the FSS screen transmits or reflects electromagnetic (EM) waves selectively and the composite material withstands external loads. In this study, the RAS composed of the E-glass/epoxy composite and single dipole FSS element was fabricated by printed circuit board (PCB) manufacturing process, and their EM transmission characteristics, such as a resonant frequency, a minimum transmission loss, and a transmission bandwidth, were measured in the X-band frequency range by the free space method with respect to the size of dipole element and its periodicity of array.     

Development of the composite RAS (radar absorbing structure) for the X-band frequency range

Since the EM properties of fiber reinforced polymeric composites can be tailored effectively by adjusting its composition, they are plausible materials for fabricating the radar absorbing structure (RAS) of desired performance. In this study, the composite RAS which has superior load bearing capacity and EM absorption characteristics has been developed by blending the conductive carbon black with the binder matrix of the E-glass/polyester composite, and its EM absorption characteristics has been measured by the free space method in the X-band frequency range (8.2–12.4 GHz). The composite RAS was designed so as to have the optimal performance for the X-band centered at 10 GHz. From the investigation, it was found that the composite RAS of 2.93 mm thickness with the conductive carbon black absorbed more than 90% of incident EM wave throughout the entire X-band frequency range.     

Radar absorbing sandwich construction composed of CNT,PMI foam and carbon/epoxy composite

RAS (radar absorbing structure) is effective for both load bearing and EM (electromagnetic) wave absorbing capability of the stealth technology. Although the RAS is usually designed to absorb the EM waves in broadband range of wave frequencies, it may be more effective to absorb the EM waves in certain frequency range as a narrow band stop filter for the specific applications.     

Fabrication of radar absorbing structure (RAS) using GFR-nano composite and spring-back compensation of hybrid composite RAS shells

The fiber-reinforced composite materials have been advanced to provide excellent mechanical and electromagnetic properties. The radar absorbing structure (RAS) is such an example that satisfies both radar absorbing property and structural characteristics. The absorbing efficiency of RAS can be obtained from selected materials having special absorptive properties and structural characteristics such as multi-layer and stacking sequence.

In this research, to develop a RAS, three-phase composites consisted of {glass fiber}/{epoxy}/{nano size carbon materials} were fabricated, and their radar absorbing efficiency was measured on the X-band frequency range (8–12 GHz). Although some of GFR (Glass Fiber–Reinforced)-nano composites showed outstanding absorbing efficiency, during their manufacturing process, undesired thermal deformation (so called spring-back) was produced. The main cause of spring-back is thought to be temperature drop from the cure temperature to the room temperature. In order to reduce spring-back, two types of hybrid composite shells were fabricated with {carbon/epoxy} and {glass/epoxy} composites. Their spring-back was measured by experiment and predicted by finite element analysis (ANSYS). To fabricate desired final geometry, a spring-back compensated mold was designed and manufactured. Using the mold, hybrid composite shells with good dimensional tolerance were fabricated.     

Characteristics of joining inserts for composite sandwich panels

Composite sandwich constructions are widely employed in various light weight structures, because composite sandwich panels have high specific stiffness and high specific bending strength compared to solid panels. Since sandwich panels are basically unsuited to carry localized loads, the sandwich structure should provide joining inserts to transfer the localized loads to other structures.In this work, the load transfer characteristics of the partial type insert for composite sandwich panels were investigated experimentally with respect to the insert shape. The static and dynamic pull out tests of the composite sandwich panels composed of an aluminum honeycomb core, two laminates of carbon fiber/epoxy composite and aluminum insert, were performed. From the experiments, the effect of the insert shape on the mechanical characteristics of composite sandwich panels was evaluated.     

Nanocomposite stealth radomes with frequency selective surfaces

The stealth function of the radome (Radar + Dome) is to transmit or reflect the EM (electromagnetic) wave selectively through the radome. In this work, the stealth radome for aircrafts and warships was developed with the FSS (frequency selective surfaces), PVC foam, and nanoclay-dispersed E-glass fabric/epoxy composite. The water diffusivity of nanocomposites, which changes the stealth characteristics, was measured with respect to the contents of nanoclay. The EM transmission characteristics were measured by the free space measurement system in the X-band frequency range (8.2–12.4 GHz) with respect to the content of nanoclay. Also, the flexural strength of the sandwich construction composed of the nanocomposite, PVC foam, and FCCL (flexible copper clad laminate) was measured by the 3-point bending test.     

Aramid/epoxy composites sandwich structures for low-observable radomes

Low-observable radomes are usually made of E-glass/epoxy composite due to its low dielectric constant which is necessary not to interfere electromagnetic (EM) wave transmission characteristics. Since aramid fibers have lower dielectric constant and higher strength than those of E-glass fiber, aramid fiber radome structures may have better the EM transmission and mechanical characteristics than those of E-glass/epoxy radomes. In this work, the low-observable radome was constructed with a sandwich construction composed of aramid/epoxy composites faces, foam core and Frequency Selective Surface (FSS) which had the abilities of transmitting EM waves selectively in the X-band range. The EM wave transmission characteristics of the low-observable radome were simulated by a 3-dimensional electromagnetic analysis software and also measured by the free space measurement method with respect to the pattern size of FSS and foam cores. The mechanical properties of the low-observable radome made of aramid/epoxy composite were measured by the 3-point bending test and compared to those of the conventional low-observable radome made of E-glass/epoxy composite.     

蜂窝状三维整体机织结构型吸波复合材料的设计、制备与性能

为了解决蜂窝夹层结构材料的开裂和分层问题,以玄武岩纤维长丝纱和碳纤维长丝纱为原料,在普通织机上,经合理设计,织造了顶层为透波层、中间层为吸波层和底面为反射层的蜂窝状三维整体机织结构型吸波织物;其次,以蜂窝状三维整体机织结构型吸波织物为增强体,双酚A型环氧树脂为基体,羰基铁粉(CIP)和炭黑(CB)为吸波剂,采用真空辅助树脂传递模塑(VARTM)成型工艺,制备了不同结构参数的蜂窝状三维整体机织结构型吸波复合材料;最后,采用矢量网络分析仪和万能试验机分别对蜂窝状三维整体机织结构型吸波复合材料的吸波性能和力学性能进行研究。研究表明,其有良好的整体性能,兼具吸波和承载能力。     

Fabrication and design of multi-layered radar absorbing structures of MWNT-filled glass/epoxy plain-weave composites

The object of this study is to design radar absorbing structures (RAS) with load-bearing ability in the X-band. Glass/epoxy plain-weave composites of excellent specific stiffness and strength, containing multi-walled carbon nanotubes (MWNT) to induce dielectric loss, were fabricated. Observations of the microstructure and the permittivity of the composites confirmed that the fabrics are suitable for use as RASs. A genetic algorithm and a theory of the reflection/transmission of electromagnetic waves in a multi-layered RAS were applied to design an optimal RAS composed of MWNT-filled composites. The thickness per ply was observed to vary, depending on the number of plies and the MWNT contents. A fabrication process was proposed that considered the variation. The proposed process was in the fabrication of a designed RAS, and the theoretical and measured reflection losses of the RAS were found to be in good agreement.     

玻璃纤维立体织物增强环氧树脂泡沫夹层复合材料的制备及力学性能

为了进一步提高泡沫夹层复合材料的承载能力和综合性能,实现其在轨道交通及汽车等工业领域的应用,开展了玻璃纤维立体织物增强环氧树脂泡沫(GF-Fabric/EP)复合材料的制备及其力学性能的研究。制备GF-Fabric/EP复合材料及其夹层结构,探索了GF-Fabric/EP复合材料及其夹层结构的失效行为,以揭示立体织物的增强机制。结果表明：立体织物的引入可显著改善GF-Fabric/EP复合材料的强度、刚度及破坏应变;但在不同承载条件下,各纱线发挥承载作用和效果不同。面板、芯材各自的性能、尺寸及面/芯界面性能均是影响GF-Fabric/EP夹层复合材料力学性能及失效特征的重要因素。以三点加载下的弯曲性能为例,针对不同的GF-Fabric/EP夹层复合材料,需调整跨厚比和试样尺寸并获得理想的失效特征,方可对其弯曲性能或层间剪切性能进行有效、合理的评价。     

夹层结构复合材料的吸波隐身技术研究进展

综述目前国内外夹层结构复合材料吸波隐身技术的特点、主要研究方向以及应用情况,包括蜂窝夹层结构和泡沫塑料夹层结构。介绍蜂窝夹层结构的吸波隐身技术的研究进展,指出影响蜂窝夹层结构吸波性能的主要影响因素,包括蜂窝本身的规格尺寸以及浸渍胶液体系等。分析聚氨酯和聚甲基丙烯酰亚胺(PMI)两种常用的泡沫夹芯吸波复合材料的吸波性能和力学性能,指出具有高力学性能、高耐热性的吸波性PMI泡沫塑料泡沫夹层结构是吸波隐身夹层结构技术未来的主要研究方向。     

Impact and post impact behavior of composite sandwich panels

Assessing the residual mechanical properties of a sandwich structure is an important part of any impact study and determines how the structure can withstand post impact loading. The damage tolerance of a composite sandwich structure composed of woven carbon/epoxy facesheets and a PVC foam core was investigated. Sandwich panels were impacted with a falling mass from increasing heights until damage was induced. Impact damage consisted of delamination and permanent indentation in the impacted facesheets. The Compression After Impact (CAI) strength of sandwich columns sectioned from these panels was then compared with the strength of an undamaged column. Although not visually apparent, the facesheet delamination damage was found to be quite detrimental to the load bearing capacity of the sandwich panel, underscoring the need for reliable damage detection techniques for composite sandwich structures.     

Light-weight honeycomb core sandwich panels containing biofiber-reinforced thermoset polymer composite skins: Fabrication and evaluation

The application of biofiber based paper-reinforced polymer (PRP) composites as skin materials for light-weight sandwich panel constructions was explored. Various sandwich panels with PRP composite skins and a commercial resin-impregnated aramid paper honeycomb core of different cell sizes and core heights were fabricated in the laboratory. The effects of honeycomb core height and cell size on the flexural properties of the lab-made sandwich panels were evaluated. The flexural moduli and strengths of the lab-made panels were compared to the reported values for three existing commercial products used for automotive load floor applications. The lab-made PRP composite/honeycomb core sandwich panels had comparable bending rigidity and flexural load bearing capability but lower areal weights when compared to the commercial products suggesting that PRP composites have the potential to be used as an alternative to glass fiber-reinforced polymer composites as skin materials in sandwich panel fabrication.     

Preparation and mechanical properties of carbon nanotube grafted glass fabric/epoxy multi-scale composites

In the present paper, carbon nanotubes (CNTs) were chemically grafted onto surfaces of the amino silane treated glass fabric by a novel chemical route for the first time to create 3D network on the glass fibers. The chemical bonding process was confirmed by Fourier transform infrared spectroscopy and scanning electron microscopy. The glass fabric/CNT/epoxy multi-scale composite laminates were fabricated with the CNT grafted fabrics using vacuum assisted resin infusion molding. Tensile tests were conducted on fabricated multi-scale composites, indicating the grafting CNTs on glass fabric resulted a decrease (11%) in ultimate tensile strength while toughness of the multi-scale composite laminates were increased up to 57%. Flexural tests revealed that the multi-scale composite laminates prepared with CNT grafted glass fabric represent recovering after first load fall. The interfacial reinforcing mechanisms were discussed based on fracture morphologies of the multi-scale composites.     

Leakage characteristics of the glass fabric composite barriers of LNG ships

The consumption of LNG (Liquefied Natural Gas) has recently increased due to a substantial rise in the price of petroleum. One of the major carriers of LNG is the LNG ships whose containment systems are composed of corrugated stainless steel plates (primary barriers) and glass fabric composite sandwich constructions (secondary barriers). The primary barriers are constructed by welding many corrugated thin stainless steel plates to reduce thermal stress, while the secondary barriers are constructed by adhesively bonding glass fabric composite sandwich constructions.One of the key technologies for the secondary barriers is to thoroughly seal the adhesive joining area, which can retard LNG leakage when the primary barriers are failed. The sealing quality of the adhesive joint is dependent on the wetting characteristics between the sandwich constructions and adhesive, which is in turn dependent on the curing cycle for the adhesive.In this work, a new method to measure the gas leakage of adhesively bonded joint was devised. The adhesive joint specimens were prepared under several different curing cycles to investigate the impregnation of adhesive into the glass fabric composite. Also, the thermal residual stress in the adhesive joint was estimated by the double strip deformation experiment. Finally, an improved curing method was developed with high tightness of the secondary barriers without increase of thermal residual stress.     

整体中空复合材料隔声性能的实验研究

为了探讨整体中空复合材料结构与隔声性能之间的关系, 设计并制备了不同高度、不同面板厚度以及不同芯材的玻璃纤维整体中空织物/环氧树脂复合材料。采用混响室-消声室法对其隔声性能进行了测试分析。研究表明: 整体中空复合材料的结构对其隔声性能有明显的影响。复合材料的隔声性能随着结构高度的增加逐渐提高, 面板厚度对材料的隔声效果影响较大, 芯材排列形式对其隔声性能影响相对较小; 8 形整体中空复合材料的隔声性能略高于 88 形和 X 形。      

三维夹芯层连织物透波复合材料性能研究

考察了玻璃纤维三维夹芯层连织物/氰酸酯(CE)复合材料的透波性能, 并与夹芯层连织物/环氧树脂复合材料和蜂窝夹层结构复合材料进行了对比。研究发现: 实验频段范围内三维夹芯层连织物/氰酸酯复合材料的平均透波率高于蜂窝夹层结构复合材料和夹芯层连织物/环氧树脂复合材料; 夹芯层连织物/氰酸酯复合材料的透波率受电磁波入射角度影响较小, 并且在芯柱高度为8 mm时有最大值, 平行经向入射的透波率略大于平行纬向入射的透波率, 8~12 GHz频率的透波率略大于12~18 GHz的透波率; 由于反射作用, 面板增强后夹芯层连织物/氰酸酯复合材料的透波率下降明显。      

Improvements in mechanical properties of a carbon fiber epoxy composite using nanotube science and technology

Carbon fiber reinforced epoxy composite laminates, with strategically incorporated fluorine functionalized carbon nanotubes (f-CNTs) at 0.2, 0.3 and 0.5 weight percent (wt.%), are studied for improvements in tensile strength and stiffness and durability under both tension–tension (R = +0.1) and tension–compression (R = −0.1) cyclic loadings, and then compared to the neat (0.0 wt.% CNTs) composite laminate material. To develop the nanocomposite laminates, a spraying technology was used to deposit nanotubes on both sides of each four-harness satin weave carbon fiber fabric piece for the 12 ply laminate lay up. For these experimental studies the carbon fiber reinforced epoxy laminates were fabricated using a heated vacuum assisted resin transfer molding (H-VARTM®) method followed by a 2 soak curing cycle. The f-CNTs toughened the epoxy resin-fiber interfaces to mitigate the evolution of fiber/fabric-matrix interfacial cracking and delamination under both static and cyclic loadings. As a consequence, significant improvements in the mechanical properties of tensile strength, stiffness and resistance to failure due to cyclic loadings resulted for this carbon fiber reinforced epoxy composite laminate.     

Processing and high strain rate impact response of multi-functional sandwich composites

Sandwich composites are finding increasing applications in aerospace, marine and commercial structures because they offer high bending stiffness and lightweight advantages. Currently, foam and honeycomb core sandwich composites are widely used in structural applications. However, affordability continues to be the driver to develop sandwich constructions that can be processed at lower costs and containing integrated design features. This paper considers sandwich constructions with reinforced cores by way of three-dimensional Z-pins embedded into foam, honeycomb cells filled with foam, and hollow/space accessible Z-pins acting as core reinforcement. These designs offer added advantages over conventional constructions load bearing by enabling functions such as ability to route wires, mount electronic components, increase transverse stiffness, tailor vibration damping, etc. With the assumption that these sandwich constructions would be part of a larger structure, impact damage is often of concern. This paper deals with: (a) processing of sandwich composites using out-of-autoclave cost-effective liquid molding approach, and (b) investigation of the high strain rate impact (164–326/s) response of the sandwich composite structures. Wherever applicable, comparisons are made to traditional foam core and honeycomb core sandwich constructions.