Development of a high temperature printable composite for microwave absorption applications

Abstract

This study deals with the development of a printable composite material based on a polyphenylene sulfide (PPS) matrix and carbonyl iron (Fe) particles, with controlled electromagnetic performance. More specifically, materials were simultaneous melt mixed and shaped under the form of filament with a diameter suitable for Fused Deposition Modeling. After reminding the potentialities of the printable PPS matrix, especially in terms of temperature resistance, microwave characterizations were performed on toroidal samples. The measured electromagnetic properties were compatible with absorption applications and compared to those of a commercial iron-filled PolyLactic Acid (PLA). Rectangular waveguide microwave loads were designed and fabricated by Fused Deposition Modeling with both materials. The PPS-Fe load has a volume that is 7 times lower than the PLA-Fe load due to a higher permittivity-permeability product and losses. Heat treatments demonstrated that no degradation is observed for the PPS-Fe load up to 180 °C while the PLA-Fe load is totally melted at 150 °C. In the same time, it was observed that the maximum power supported by the PPS-Fe load is three times higher than the one supported by the PLA-Fe load. Finally, the temperature stability of the electromagnetic response of the PPS-Fe composite was demonstrated by measurements in the −70 °C to 140 °C temperature range. This new high temperature printable composite paves the way to the development of efficient, low-cost, low-weight, power and temperature stable absorbers for microwave applications.