Multiphysics anti-icing simulation of a CFRP composite wing structure embedded with thin etched-foil electrothermal heating films in glaze ice conditions

Abstract

Electrothermal ice protection systems (IPS) for CFRP composite aircraft face distinct challenges because of the composite structure’s relatively low thermal conductivity and vulnerability to overheating. In this work, the thermal response of a thin etched-foil heating film-based IPS integrated into CFRP laminates was characterized both experimentally and by thermal FEM simulation. A resulting IPS configuration was implemented in a CFRP wing skin laminate model of an unmanned aerial vehicle (UAV) for multiphysics icing simulation. Glaze ice accretion and melting were simulated with in-flight conditions and varying heater heat fluxes and angles of attack. Sharp surface temperature drops were observed in the heating film gap regions, which led to the implementation of a quasi-continuous film spacing. A uniform heater heat flux of 7.5 kW/m2 achieved anti-icing functionality with an associated surface temperature range of 0–13 °C. This range revealed the merit of heat flux zone modulation to uniformly distribute the surface temperature and improve the overall energy efficiency of the system.