Processing and Characterization of Aerospace Composites for Advanced Radome Applications

This research presents the development and characterization of innovative composite materials for aerospace radome applications. Radomes, which protect radar and antenna systems in hostile environmental conditions, must maintain structural integrity while minimizing signal attenuation, especially in the high-frequency Ku-band (10-14.5 GHz). The study explores the use of commercially available reinforcements such as Kevlar and quartz combined with cyanate ester matrices. Three manufacturing techniqueshand layup, infusion molding, and autoclave processingwere employed to fabricate composite samples. Mechanical characterization included tensile, impact, and flexural strength tests, as per American Society for Testing and Materials (ASTM) standards, while electromagnetic testing was conducted using a state-of-the-art anechoic chamber. Among both combinations, the cyanate ester/quartz composite manufactured through autoclave processing demonstrated superior electromagnetic performance with an insertion loss of less than 1 dB across the Ku-band while maintaining adequate mechanical properties. Kevlar-based composites showed higher mechanical strength but slightly compromised signal transparency. This work contributes to the field by providing a data-driven framework for optimizing material selection and processing techniques in aerospace composite manufacturing, aligning with national goals for indigenously developed high-performance materials.