Structural-Integrated Electrothermal Anti-Icing Components for UAVs: Interfacial Mechanisms and Performance Enhancement

Icing represents a significant hazard to the flight safety of unmanned aerial vehicles (UAVs), particularly affecting critical aerodynamic surfaces such as air intakes, wings, and empennages. While conventional adhesive electrothermal de-icing systems are straightforward to operate, they present safety concerns, including a 15–25% increase in system weight, elevated anti-/de-icing power consumption, and the risk of interlayer interface delamination. To address the objectives of reducing weight and power consumption, this study introduces an innovative electrothermal–structural–durability co-design strategy. This approach successfully led to the development of a glass fiber-reinforced polymer (GFRP) component that integrates anti-icing functionality with structural load-bearing capacity, achieved through an embedded hot-pressing process. A stress-damage cohesive zone model was utilized to accurately quantify the threshold of mechanical performance degradation under electrothermal cycling conditions, elucidating the evolution of interfacial stress and the mechanism underlying interlayer failure. Experimental data indicate that this novel component significantly enhances heating performance compared to traditional designs. Specifically, the heating rate increased by approximately 202%, electrothermal efficiency improved by about 13.8% at −30 °C, and interlayer shear strength was enhanced by approximately 30.5%. This research offers essential technical support for the structural optimization, strength assessment, and service life prediction of UAV anti-icing and de-icing systems in the aerospace field.