Structural properties and electromagnetic shielding performance of bidirectional carbon fabric and Fe₂O₃nano filler reinforced epoxy composites

This study investigates the structural and electromagnetic interference (EMI) shielding performance of bidirectional carbon fabric/epoxy composites reinforced with Fe₂O₃ nanoparticles for aerospace applications. Composites with varying Fe₂O₃ loadings (1–3 wt%) were fabricated using a hand lay-up method, followed by mechanical and electromagnetic shielding characterisation in the X-band frequency range (8.2–12.4 GHz). Tensile testing revealed that 1–2 wt% Fe₂O₃ loading enhanced the stiffness and tensile strength of the composite due to improved fibre–matrix interfacial bonding, while 3 wt% caused agglomeration and reduced strength. EMI shielding measurements showed absorption-dominated performance across all configurations, with multiple layers significantly improving total shielding effectiveness (SE_T). The highest SE_T (25.3 dB) was achieved for a two-layer laminate with 3 wt% Fe₂O₃, attributed to synergistic dielectric and magnetic losses and enhanced internal reflections. The results demonstrate that optimised Fe₂O₃ content and laminate layering can deliver lightweight, structurally robust composites with effective EMI shielding, making them suitable for advanced aerospace structures requiring mechanical integrity and electromagnetic compatibility. These findings highlight that optimized nanoparticle loading, and laminate architecture can yield lightweight composites that unite mechanical robustness with effective EMI shielding, offering strong potential for aerospace structures demanding both structural performance and electromagnetic compatibility.