Stepwise-graded LDPE/aluminum composites: RSM-based optimization for enhanced strength and EMI shielding

Among the most salient features of composite materials are lightness, adjustability, and operational manufacturability. In telecommunication structures, it is imperative that the material meet mechanical strength and electromagnetic properties in tandem. Electromagnetic shielding must be considered in telecommunication boxes, in conjunction with structural strength. This article discusses the manufacture and experimental test of polymer multilayers stepwise graded from low-density polyethylene polymer with different percentages of aluminum powder and arrangement. The injection method was employed to manufacture the stepwise graded layers, and the Response surface methodology method was utilized to optimize the powder percentages, arrangements, and identify the optimal percentage for the functional structure layers. A comprehensive review and analysis of the results were conducted to enhance shielding in the frequency range of 1-8 GHz and attain maximum tensile strength. The outcomes demonstrate that the optimal structure attains a tensile strength equivalent to 8.64 MPa, according to the ASTM D 638 standard, and a shielding of-14 dB, in standard waveguide device. The manufacturing process was duly considered, and the obtained results render this structure suitable for utilization in telecommunication applications.