Mechanical Design and Manufacturing of Signal Interception Antenna in Composite Material for Naval Application

Abstract

This work shows the mechanical design and the FE analyses performed for an innovative naval Antenna Unit for signal interception application: more than twenty electromagnetic sensors operating from HF up to Ka band and microwave modules are integrated in a unique structure designed for a top mast installation (i.e. for naval platform). The number of constraints in terms of weight and electromagnetic transparency calls for the employment of composite materials such as glass, aramidic and carbon epoxy prepregs. Primary structures was modelled by using FE codes: both orthotropic and isotropic models have been implemented as well as non-linear contacts and bolted joints. The mast-mounted installation requires high mechanical stiffness and strength but the exposure to saline environment needs many manufacturing issues to be respected. In particular, the selection process of suitable materials and the sealing manufacturing procedures to protect them from the external agents was reported. Another key feature of the presented design concerns the electromagnetic compatibility requirement: to avoid electromagnetic emissions (EMC) generated by antenna’s internal units and to protect antenna sensors by external platform’s emitters, an appropriate stacking sequence was chosen for composite laminates with a prepreg copper mesh.