Laser-Engraved Micro-Patterned rGO/WPU Composite Structures for Aircraft Applications: Synchronizing Electrothermal De-Icing and Broadband Microwave Transparency

Aircraft confronting harsh meteorological conditions and radar detection environments during high-altitude flights face significant risks, which can threaten flight safety. This study designs and fabricates a novel Jerusalem cross-inspired Frequency Selective Surface (FSS). Initially, rGO powder with an optimized reduction degree is synthesized as the conductive filler. Based on this, the rGO/WPU electrothermal coating is prepared using the spraying method, demonstrating excellent electrical conductivity and electrothermal performance. Subsequently, a New Jerusalem Pattern Structure (NJPS) is engineered on the coating surface. This patterned design notably improved microwave transmittance. Parameter optimization ensured superior wave transmission performance, with the underlying mechanism explained through antisymmetric surface current analysis. Laser-engraved NJPS samples are tested under both room-temperature and low-temperature conditions, confirming dual functionality: effective Joule heating and stable broadband transmission. Importantly, icing wind tunnel tests under simulated flight conditions verified the de-icing capability within 216s via interfacial water-film lubrication. This patterning strategy establishes a viable methodology for reconciling electrothermal de-icing and electromagnetic transparency on aircraft surfaces.