A Hybrid Multifunctional Composite Skin Material by Standard Prepreg Lay-up Process

The objective of this project is to develop a hybrid, multifunctional composite material that improves the thermal and chemical stability, and surface durability of traditional carbon fiber reinforced polymer (CFRP) composites. By using a standard prepreg lay-up process, in which a flexible conductive ceramic thin layer is bonded directly onto the outmost layer of polymer composites to ensure the material integrity, a hybrid composite will be manufactured following the same procedure as standard CFRP composites without increasing extra manufacturing cost. The prepreg lay-up manufacturing steps to produce such a hybrid multifunctional composite material are listed as below: (1)spray release agent on the tooling surface; (2)apply the flexible thermally-conductive ceramic composite layer on the tooling surface over release agent; (3)prepreg multiple layers of carbon fiber sheets over the flexible ceramic composite layer; (4)co-cure the hybrid composite using the standard autoclave method. The produced hybrid composites can be used in harsher environment, (e.g., high temperature, moisture under load, ultraviolet radiation, corrosive chemicals). The manufacturing procedure is readily scalable. During experiment, we will implement process optimization/control during scale-up (size and geometric complexity) from coupon size to full-scale article according to application requirements.