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Polyurethane Foam-Based Radar Absorbing Sandwich Structures To Evade Detection
Polyurethane Foam-Based Radar Absorbing Sandwich Structures To Evade Detection
to evade detection
MAM Hunjra, MA Fakhar, K Naveed
and T Subhani
Abstract
Polyurethane foam-based sandwich structures were developed for radar absorbing
properties together with load bearing capability. The sandwich construction of radar
absorbing structure comprised glass fiber epoxy matrix composite containing carbon
black as front face skin, carbon fiber epoxy matrix composite as back face skin, and
polyurethane foam reinforced with carbonyl iron or graphite powder as the core mater-
ial. The quantity of carbon black in the front face skin composite was varied from 6 wt.%
to 8 wt.%, while the loading of carbonyl iron and graphite powder in foam core was
varied from 30 wt.% to 55 wt.% and 5 wt.% to 30 wt.%, respectively. The compression
molding technique was used to prepare face skins and sandwich structures. Different
combinations of the sandwich structures were characterized for a frequency range
of 2–18 GHz using free space measurement method. The maximum attenuation
of 31.85 dB was observed in a combination containing 6 wt.% carbon black in front
face skin and 20 wt.% graphite powder in the foam core. The total reduction in radar
cross-section demonstrated almost zero radar signature at nine different frequencies,
whereas broad range attenuation of 10 dB was achieved.
Keywords
Radar absorbing structure, radar cross-section, carbon black, graphite powder, carbonyl
iron, polyurethane foam, sandwich structure
Department of Materials Science and Engineering, Institute of Space Technology, Islamabad, Pakistan
Corresponding author:
MAM Hunjra, Department of Materials Science and Engineering, Institute of Space Technology, 1-Islamabad
Highway, Islamabad 44000, Pakistan.
Email: arslan.hunjra@yahoo.com
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Introduction
With the development of radar technology for the detection of air vehicles, efforts
have also been made to develop techniques to evade radar detection [1,2]. The
improvement in stealth technology is therefore a continuous process in parallel
to the development of latest radar systems [3]. Stealth efficiency is explained by
radar cross-section (RCS) reduction and radar energy attenuation [4]. RCS is the
measure of target’s ability to reflect back radar waves and it is necessary to reduce
RCS in order to evade detection. Previously, the focus was on the development of
radar absorbing materials (RAM) without the requirement of load bearing cap-
ability of RAMs. As a result, RAMs proved to be either very brittle or extremely
flexible [5]; chipping off from the surface and increased weight were the other issues.
To overcome such limitations, radar absorbing structures (RAS) have been
suggested, which possess radar absorption properties together with load bearing
capabilities [3,6,7]. Therefore, RASs are now replacing traditional aircraft struc-
tural materials, as their use is in conformity with the future trends of air vehicle
designs and desired structural material [5]. Energy loss of RASs is measured in
terms of dB, which is also called attenuation. The increased energy loss in the
structure shows the better absorbance. The radar signature helps in detection of
the aircraft. In order to evade radar detection, RCS must be reduced and the
complete reduction of RCS will produce zero radar signature specifically from
the reflection of radar waves.
Apart from defense applications of RASs as stealth materials, they also find
applications in commercial fields of electromagnetic interference (EMI) shielding,
which is gaining importance because of the problems in communication and radar
detection and one of the major applications is in wind turbine blades [3]. During
movement, these structures cause false radar signals and decrease the efficiency of
radar systems. Recently, it has been suggested to use RASs to avoid interference
and to falsify radar echo signals [8]. Moreover, the trend of miniaturization in the
fields of advanced electronic and communication devices uses densely packed struc-
tures and hence increases chances of EMI. The use of RASs, therefore, becomes
imperative for shielding so as to eliminate interference effects.
Radar absorbing properties combined with high strength-to-weight ratio mater-
ials can be achieved in sandwich structures; therefore, these structures are acquiring
unprecedented attention. These structures either use porous or honeycomb materials
as core, which is sandwiched between the face skins [5,9]. The core and face skins
may be made of composite materials by incorporating filler particles. The dispersion
of filler particles not only enhances the stiffness of the materials but also improves the
absorption properties including RCS reduction and attenuation, which strongly
depend on parameters including material type, filler type and loading, thickness
and operating frequency of the system. The chances for the reflection of electromag-
netic (EM) waves increases by raising the conductive filler quantity, as electrons can
find a continuous path for movement.
In the present study, sandwich RASs were prepared in two different designs by
using a variety of filler materials in face skins and core. The underlying aim was to
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Hunjra et al. 3
prepare a sandwich structure with an ability to absorb radar waves and to reduce
radar signature; the preparation of a light weight structure was the other aim.
For front face skin, carbon black (CB) was used in glass fiber epoxy matrix com-
posite as dielectric loss filler material in three different loadings. Graphite powder
(GP) or carbonyl iron (CI) was used in polyurethane (PU) foam core in 10 different
loadings. These fillers were added to not only enhance the radar absorption proper-
ties but also to improve the load bearing capability of the sandwich structures.
The requirement was to attain absorption in X-band (8–12 GHz) and Ku-band
(12–18 GHz), which are critical for stealth applications [10]; the fabricated struc-
tures were therefore characterized for a broad frequency range, i.e. 2–18 GHz.
The thickness of the sandwich structures was kept constant in the first design in
order the make the comparison of different combinations, whereas the thickness
of the sandwich structure in the second design was increased due to a different
combination of the face skins and the core. In order to achieve uniform distribution
of fillers and to avoid the presence of voids in the composite face skins, the com-
pression molding technique was used. The core of the sandwich structures was
also the composite material comprising PU foam loaded with either GP or CI.
Previously, similar structures were developed using carbon nanotubes as filler
material in foam cores and glass fiber epoxy matrix composites were used as
face skins [11,12]. CB and GP-loaded rubber and epoxy composites based layered
structures have also been studied [13,14]. However, in the present study, different
filler materials are used to prepare novel class of sandwich structures. Hence,
these structures are unique RASs, which can cause step down energy reduction
of EM waves. The characterization of RASs was performed by measuring
RCS reduction and attenuation using free space measurement in an anechoic
chamber [7] and the optimum designs of the sandwich structures are suggested
for real time applications.
Experimental
Materials
The materials for the manufacturing of sandwich structures were carbon fibers
(CF) and glass fibers (GF) as fabrics of twill 2/2 weaving pattern, epoxy resin,
carbon black (CB), graphite powder (GP), carbonyl iron (CI) and polyurethane
(PU) foam; polyether polyol (PP) and toluene di-isocyanate (TDI) were used to
prepare PU foam. The raw materials were supplied by Advanced Engineering
Research Organization (AERO), Pakistan. The epoxy used for the manufacturing
of face skin composites and their bonding with the core was Araldite LY 5052
(Huntsman Chemicals), which is a low-viscosity resin suitable for good wetting of
fibers and high loadings of particles; Aradur 5052 was used as a hardener/curing
agent. GFs of 92125 and CFs of 426 type (Swiss Composites) were used to reinforce
epoxy matrix to manufacture composite face skins. GP and CI had particle sizes of
20 mm and 5–9 mm, respectively, and used in as-received condition.
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Manufacturing
The sandwich structures comprised three parts, each made of composites: (a)
front face skins, which were manufactured of glass fiber epoxy matrix composite
containing carbon black (CB/GF/epoxy), (b) back face skins, which were manu-
factured of carbon fiber epoxy matrix composite (CF/epoxy), and (c) core, which
was manufactured of PU foam reinforced with GP and CI (GP/PU or CI/PU). The
epoxy resin was used to bond the face skins with the core.
For the manufacturing of CB/GF/epoxy composite front face skins, GFs were
impregnated with CB-loaded epoxy resin by hand layup method and eight GF
layers were stacked, at zero degree to each other, in a mold followed by compres-
sion molding at 1.3 MPa for 8 h. The manufactured composite was demolded and
cut into required dimensions of 150 150 mm. Three different loadings of CB in
CB/GF/epoxy composite were incorporated, i.e. 6 wt.%, 7 wt.%, and 8 wt.%, as
given in Table 1. CF/epoxy composites for back face skins were manufactured
following the same route but without the addition of any filler (Table 1).
PP and TDI were reacted to prepare foam core [15] in the presence of silicone
and dimethyl ethanol amine (DMEA), as surfactant and catalyst, respectively [16].
Water was used as a blowing agent to blow out carbon dioxide through the mix-
ture. For the manufacturing of composite foam, the filler in required quantity was
Table 1. Types of composites used for the manufacturing of the three parts of sandwich
structures, i.e. front face skin, back face skins, and foam core.
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Hunjra et al. 5
added to TDI and mixed by mechanical stirring. The blowing agent, catalyst, and
surfactant were mixed in PP separately. Later the two mixtures were mixed and
stirred for 10 s at 1000 r/min. The mixture was immediately poured into the wood
mold wherein the foam was grown. After a curing time of 12 h at room temperature,
the foam was removed from the mold and cut into dimensions of 150 150 20 mm.
The mixing ratio of PP and TDI was kept at 100:50 by weight. Ten different types of
composite foams were prepared: four types contained 30 wt.%, 40 wt.%, 50 wt.%,
and 55 wt.% CI and the remaining six types contained 5 wt.%, 10 wt.%, 15 wt.%,
20 wt.%, 25 wt.%, and 30 wt.% GP, as given in Table 1 along with their densities.
Figure 1. Schematics of the two designs (a) and (b) of radar absorbing sandwich structures
manufactured in the present study.
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sandwich structures prepared in the present work; ten as per the first design and
one following the second design.
Characterization
The absorption characterization of prepared composites was performed in an
anechoic chamber; network analyzer and antennas programmed with computers
were utilized to carry out measurements. Free space measuring method was
employed to characterize the specimens of RAS, where the target is lighted with
radar waves and reflected waves are detected by a receiver [7]. Flat specimens
were scanned for the broad frequency range of 2–18 GHz and relative attenuation
was recorded and later plotted in graphical form. Aluminum plate was used as a
reference.
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Figure 2. The attenuation (a) and radar cross-section reduction (b) of three types of glass
fiber epoxy matrix composites containing 6 wt.%, 7 wt.%, and 8 wt.% for front face skins of
sandwich structures.
type to be used as front face skin in sandwich structures. It was found that the
composites containing 6 wt.% CB showed 17% and 46% RCS reduction in
X-band and Ku-band, respectively (Figure 2). The attenuation achieved from
this composite was 3.33 dB. Moreover, the composite showed the energy absorb-
ance throughout the Ku-band. Therefore, 6 wt.%CB/GF/epoxy composite was
found to be suitable for the use in the two designs of sandwich structures.
As per the first design, 10 sandwich structures were prepared, which comprised
the 6 wt.%CB/GF/epoxy composite front face skins, CF/epoxy composite back
face skins, and core of the PU foam containing either CI or GP in 10 different
loadings (Table 2 and Figure 1). All the sandwich structures exhibited good attenu-
ation but the structures with foam core containing GP showed comparatively
better results than CI (compare Figures 3 and 4).
In case of core containing 30 wt.% CI, attenuation increased until 50%;
an attenuation up to 28 dB was achieved with 50 wt.% CI. The maximum attenu-
ation of 13.58 dB was achieved at 16.03 GHz frequency, which dropped in
Ku-band (Figure 3). From 15.80 GHz to 17.40 GHz, the same structure showed
attenuation of more than 10 dB allowing 90% RCS reduction in this range; the
total disappearance of radar signature was also noticed at different frequencies
(Figure 3). On average, RCS reduction in Ku-band was observed to be
60.51%, whereas in X-band it was 86.64%.
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Figure 3. The attenuation (a) and radar cross-section reduction (b) of four types of sandwich
structures containing glass fiber epoxy matrix composite containing 6 wt.% carbon black as
front face skin, carbon fiber epoxy matrix composite as back face skin, and polyurethane foam
containing 30 wt.%, 40 wt.%, 50 wt.% and 55 wt.% carbonyl iron as core (see Figure 1(a)).
The structures with foam cores containing GP showed better results than CI
(Figure 4). A rising trend was noticed with increasing contents of GP in the foam
but at higher loadings, the shifting in attenuation peaks was also observed. The
foam core containing 20 wt.% GP showed the optimum attenuation results. It
showed 31.85 dB energy loss at 15.82 GHz of frequency, which falls in Ku-
band. These structures not only showed attenuation and RCS reduction in Ku-
band but also covered X-band; 94.75% RCS was reduced in overall Ku-band,
whereas in X-band reduction up to 88.20% was observed. At different frequencies,
it showed 100% RCS reduction such as 15.82 GHz and 12 GHz. If the energy
absorption is to be the only parameter to select a stealth material, this structure
may be considered as the optimum choice.
The foam core containing 25 wt.% GP showed two peaks: one in X-band and
the other in Ku-band. The attenuation achieved was comparatively lower than the
foam containing 20 wt.% GP but it covered two different regions, which makes it
suitable for applications demanding wide range of frequencies. Almost 23 dB loss
was observed at both 8.80 GHz and 14.73 GHz, whereas RCS was reduced to 100%
virtually leaving zero radar signature defining it an ideal material for stealth appli-
cations. Only at 11 GHz, it showed attenuation below 10 dB throughout X-band
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Figure 4. The attenuation (a) and radar cross-section reduction (b)of six types of sandwich
structures containing glass fiber epoxy matrix composite containing 6 wt.% carbon black as
front face skin, carbon fiber epoxy matrix composite as back face skin, and polyurethane foam
containing 5 wt.%, 10 wt.%, 15 wt.%, 20 wt.%, 25 wt.%, and 30 wt.% graphite particles as core
(see Figure 1(a)).
and Ku-band, which is an outstanding result to have a broad range radar absorb-
ing structure. Moreover, fluctuations were reduced and only two peaks were
observed on the complete selected range of 2–18 GHz.
The foam core containing 30 wt.% GP also showed fluctuating curve with mul-
tiple peaks. The peak with maximum attenuation was observed at 11.03 GHz,
which showed the attenuation of 25.70 dB. This structure showed three frequen-
cies at which RCS was 100% reduced. Ku-band showed 92.80% RCS reduction.
This structure showed results, which are more promising in X-band, where RCS
was reduced to 80.02% and provided a peak of 25.70 dB at 11.03 GHz. It is
interesting to see that the maximum attenuation moved from 15 GHz to 11 GHz
by changing the contents of GP from 20 wt.% to 30 wt.%, which reveals the pos-
sibility of manipulating the RCS reduction at the desired frequency.
The second design of the sandwich structure is comparatively more complex
than the first design but demonstrated interesting results. The broadening of
peaks was the key feature shown by this structure. The first design showed peaks
of higher intensities, which primarily contributed to RCS reduction at few fre-
quency ranges. However, the second design has shown attenuation below 10 dB
in Ku-band at most of the frequencies with interesting shape of the curves, as
shown in Figure 5; straight curves were obtained allowing the structure for
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Figure 5. The attenuation (a) and radar cross-section reduction (b) of sandwich structure
containing glass fiber epoxy matrix composite containing 6 wt.% carbon black as front face skin
and middle layer, carbon fiber epoxy matrix composite as back face skin and polyurethane
foam containing 20 wt.% graphite particles as the two cores (see Figure 1(b)).
Conclusions
A novel class of PU foam core-based RAS was developed for stealth applications
in X-band and Ku-band. CB, GP, and CI were used as filler materials in the
composite face skins and foam cores. The manufactured sandwich structures were
characterized for RCS reduction and attenuation using free space measurement sys-
tem in an anechoic chamber; 100% RCS reduction and almost zero radar signature
were achieved at nine frequencies in four different structures. GP proved to
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Hunjra et al. 11
Table 3. The frequencies at which the sandwich structures showed total RCS reduction.
be the better absorbing material for radar absorption at higher frequency ranges.
From nine attenuation peaks giving almost complete RCS reduction, the optimum
was observed at 20 wt.% GP in PU core, which provided the attenuation
of 31.85 dB at 15.82 GHz. Also, 88% and 95% RCS reductions were observed
over the whole X and Ku bands, respectively; 10 dB attenuation baseline
was achieved for almost complete Ku-band when GP was increased from 20%
to 25% in foam core. The increased quantity of GP shifted the attenuation
peak from Ku-band to X-band. It was found that CI gave better attenuation
for lower frequency ranges. It was also found that the attenuation peaks can
be broadened and fluctuations can be minimized by utilizing multilayer
absorbing structures.
Acknowledgement
The authors would like to thank Advanced Engineering Research Organization (AERO),
Pakistan, for providing raw materials and technical assistance.
Funding
The author(s) received no financial support for the research, authorship, and/or publication
of this article.
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