A Facile Method for the Large-Scale Production of Metal-coated Graphite Microfibers

Theoretical computations have proven that metal coatings will increase the IR attenuation of graphite fibers. We propose a novel highly conformal and scalable process for metallizing carbon fibers in bulk with optimal IR obscurant dimensions. The metal coating will provide complete coverage of the individual fibers, have high electrical conductivity along the entire fiber length, and the coated fibers will have minimal agglomeration. Additionally, the process will be low-cost and suitable for large scale production. A key feature of our technology is that it addresses the problem commonly encountered when preparing nano-scale films on small 3D objects-the formation of incomplete films. In Phase 1, we will demonstrate the feasibility of our process to form continuous films, prepare gram quantities of coated fibers, and determine their IR extinction coefficient and conductivity. In the Phase 1 option, several different metal coats will be prepared and their extinction coefficients experimentally determined and compared. In Phase 2, the methods developed will be scaled up to prepare kg quantities of fibers.