Dimensionally and environmentally ultra-stable polymer composites reinforced with carbon fibres

• Published in: Nature materials 2020-03, Vol.19 (3), p.317-322
• Main Authors: Anguita, J. V., Smith, C. T. G., Stute, T., Funke, M., Delkowski, M., Silva, S. R. P.
• Format: Article
• Language: English
• Subjects: 639/301; 639/301/1023; 639/301/1023/303; 639/624; 639/624/399; Aeronautics; Biomaterials; Carbon; Carbon fiber reinforced plastics; Chemistry and Materials Science; Condensed Matter Physics; Diamond-like carbon films; Fiber reinforced polymers; Materials Science; Mechanical properties; Moisture; Nanotechnology; Optical and Electronic Materials; Outgassing; Polymer matrix composites; Polymers; Space applications; Spacecraft; Thermal expansion
• ISSN: 1476-1122; 1476-4660
• DOI: 10.1038/s41563-019-0565-3

The quest to develop materials that enable the manufacture of dimensionally ultra-stable structures for critical-dimension components in spacecraft has led to much research over many decades and the evolution of carbon fibre reinforced polymer materials. This has resulted in structural designs that feature a near-zero coefficient of thermal expansion. However, the dimensional instabilities that result from moisture ingression and release remain the fundamental vulnerability of the matrix, which restricts many applications. Here, we address this challenge by developing a space-qualifiable physical surface barrier that blends within the mechanical properties of the composite, thus becoming part of the composite itself. The resulting enhanced composite features mechanical integrity and a strength that is superior to the underlying composite, while remaining impervious to moisture and outgassing. We demonstrate production capability for a model-sized component for the Sentinel-5 mission and demonstrate such capability for future European Space Agency (ESA) and National Aeronautics and Space Administration (NASA) programmes such as Copernicus Extension, Earth Explorer and Science Cosmic Visions. Multiple layers of diamond-like carbon films are shown to act as moisture barriers when conformally deposited on carbon fibre reinforced polymers used in space applications.