基于碳纤维单向带的圆形蜂窝夹芯结构吸波承载一体化设计

Integrated electromagnetic wave-absorbing and load-bearing design of circular honeycomb sandwich structures based on unidirectional carbon fiber tapes

  • 摘要: 针对目前飞行器复合材料结构轻质吸波承载一体化设计中力学与电磁性能难以兼顾的矛盾与迫切需求,本文提出了一种吸波泡沫填充碳/玻璃纤维混杂圆形蜂窝夹芯结构(FFCH)。FFCH通过简易铺层设计,利用碳纤维单向带(UD-CF)在横、纵两向上力电性能差异显著的特点,将面外铺设的碳纤维单向带与玻璃纤维织物(GFF)相结合构建碳/玻璃纤维混杂圆形蜂窝壁,并在蜂窝内填充PMI吸波泡沫,利用芯体组元间力学/电磁特性的耦合效应,实现吸波与承载性能的协同设计。电磁仿真与试验表明,沿面外方向排布的碳纤维能够降低电磁波的集肤效应,拓展强电场区域,从而使FFCH在2~6 GHz低频段相较于无碳纤维FFCH的平均反射损耗由−10.2 dB降低至−12.1 dB,在2~18 GHz范围内由−14.7 dB降低至−15.5 dB,同时验证了FFCH实现了宽频带(2~18 GHz)、大角度(0°~60°)、高强度(平均反射损耗低至−15.5 dB)的电磁波吸收能力。面外压缩试验结果表明,相较于未填充吸波泡沫的碳/玻璃纤维混杂圆形蜂窝夹芯结构(CH),FFCH的比压缩强度以及单位质量吸能分别提高了65.40%、60.87%。有限元仿真结果进一步揭示了承载性能的增强机理,即吸波泡沫的侧向支撑作用抑制了圆蜂窝壁的褶皱屈曲,使结构失效模式由CH的整体屈曲转变为FFCH的局部压溃,从而提高峰值承载能力。绘制的材料选择图表明,相较于在工程中已经广泛应用的泡沫、蜂窝以及各类新型轻质高强夹芯结构构型,FFCH具有更高的比压缩强度,体现出更明显的轻量化承载优势。FFCH通过将碳纤维同时作为电磁损耗单元和主要承载单元,实现了力学与电磁吸波性能的一体化设计,为轻质吸波承载一体化复合材料夹芯结构提供了一种颇具应用前景的设计方案。

     

    Abstract: To address the critical trade-off and urgent demand for balancing mechanical and electromagnetic properties in the integrated design of lightweight, radar-absorbing, and load-bearing aerospace composite structures, this paper proposes an absorbing-foam-filled hybrid carbon/glass fiber circular honeycomb sandwich structure (FFCH). Utilizing a straightforward layup design, the FFCH exploits the highly anisotropic mechanical and electrical properties of unidirectional carbon fiber tapes (UD-CF) in the transverse and longitudinal directions. Specifically, the hybrid carbon/glass fiber circular honeycomb walls are constructed by combining out-of-plane UD-CF with glass fiber fabric (GFF). Additionally, polymethacrylimide (PMI) radar-absorbing foam is filled into the honeycomb cells. By leveraging the mechanical and electromagnetic coupling effects among the core constituents, a collaborative design that synergistically optimizes both microwave-absorbing and load-bearing performance is successfully achieved. Electromagnetic (EM) simulations and experimental characterizations demonstrate that the carbon fibers aligned along the out-of-plane direction effectively mitigate the skin effect of EM waves and expand the regions of intense electric fields. Consequently, compared to the FFCH without carbon fibers, the average reflection loss of the proposed FFCH is further reduced from −10.2 dB to −12.1 dB in the low-frequency band of 2–6 GHz, and from −14.7 dB to −15.5 dB across the broader 2–18 GHz range. Furthermore, it is verified that the FFCH successfully achieves broadband (2-18 GHz), wide-angle (spanning 0°-60°), and high-intensity (with an average reflection loss to −15.5 dB) EM wave absorption capabilities. Out-of-plane compression test results indicate that, compared to the hybrid carbon/glass fiber circular honeycomb sandwich structure without foam infill (CH), the specific compressive strength and specific energy absorption of the FFCH are significantly improved by 65.40% and 60.87%, respectively. Finite element (FE) simulations further reveal the enhancement mechanism underlying its load-bearing capacity: the lateral support provided by the absorbing foam effectively suppresses the wrinkling buckling of the circular honeycomb walls. This shifts the failure mode of the structure from global buckling in the CH to local crushing in the FFCH, thereby substantially elevating the peak load-bearing capacity. The Ashby charts demonstrate that, compared to conventional foams, honeycombs, and various newly developed lightweight, high-strength sandwich topologies widely utilized in engineering, the FFCH exhibits a superior specific compressive strength. This highlights its more pronounced lightweight load-bearing advantages. By utilizing carbon fibers simultaneously as electromagnetic loss elements and primary load-bearing components, the FFCH achieves an integrated design of both mechanical and microwave-absorbing properties. This offers a highly promising design paradigm for lightweight, radar-absorbing, and load-bearing multifunctional composite sandwich structures.

     

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