Sustainable design of broadband radar absorbers using metallurgical waste and multi-objective optimization

This study proposes a sustainable approach for converting metallurgical waste into value-added electromagnetic materials for broadband radar absorption applications. A total of 105 samples are fabricated from 14 industrial waste types using various shaping and additive techniques, and then electromagnetically characterized. A novel double-stage Artificial Bee Colony (DS-ABC) optimization algorithm is developed to design an effective five-layer absorber by independently optimizing layer sequence and thickness for transverse electric (TE) and transverse magnetic (TM) polarizations. The resulting multilayer structure achieves over 90 % absorption across the 2-18 GHz frequency range under multiple incidence angles. Beyond technical performance, this work demonstrates a scalable method for replacing hazardous waste with functional materials, thereby reducing environmental impact and aligning with the principles of a circular economy. The proposed approach offers practical relevance for sectors requiring electromagnetic interference (EMI) shielding and stealth technologies. It also contributes to sustainable production practices by repurposing industrial by-products.