Radiation and electrostatic resistance for ultra-stable polymer composites reinforced with carbon fibers.

Future space travel needs ultra-lightweight and robust structural materials that can withstand extreme conditions with multiple entry points to orbit to ensure mission reliability. This is unattainable with current inorganic materials. Ultra-highly stable carbon fiber reinforced polymers (CFRPs) have shown susceptibility to environmental instabilities and electrostatic discharge, thereby limiting the full lightweight potential of CFRP. A more robust and improved CFRP is needed in order to improve space travel and structural engineering further. Here, we address these challenges and present a superlattice nano-barrier-enhanced CFRP with a density of ~3.18 g/cm3 that blends within the mechanical properties of the CFRP, thus becoming part of the composite itself. We demonstrate composites with enhanced radiation resistance coupled with electrical conductivity (3.2 × 10-8 ohm⋅m), while ensuring ultra-dimensionally stable physical properties even after temperature cycles from 77 to 573 K.

Increasing the robustness and crack resistivity of high-performance carbon fiber composites for space applications.

The endeavors to develop manufacturing methods that can enhance polymer and composite structures in spacecraft have led to much research and innovation over many decades. However, the thermal stability, intrinsic material stress, and anisotropic substrate properties pose significant challenges and inhibit the use of previously proposed solutions under extreme space environment. Here, we overcome these issues by developing a custom-designed, plasma-enhanced cross-linked poly(p-xylylene):diamond-like carbon superlattice material that enables enhanced mechanical coupling with the soft polymeric and composite materials, which in turn can be applied to large 3D engineering structures. The superlattice structure developed forms an integral part with the substrate and results in a space qualifiable carbon-fiber-reinforced polymer featuring 10-20 times greater resistance to cracking without affecting the stiffness of dimensionally stable structures. This innovation paves the way for the next generation of advanced ultra-stable composites for upcoming optical and radar instrument space programs and advanced engineering applications.

Complete Atomic Oxygen and UV Protection for Polymer and Composite Materials in a Low Earth Orbit.

With the realization of larger and more complex space installations, an increase in the surface area exposed to atomic oxygen (AO) and ultraviolet (UV) effects is expected, making structural integrity of space structures essential for future development. In a low Earth orbit (LEO), the effects of AO and UV degradation can have devastating consequences for polymer and composite structures in satellites and space installations. Composite materials such as carbon fiber-reinforced polymer (CFRP) or polymer materials such as polyetherimide and polystyrene are widely used in satellite construction for various applications including structural components, thermal insulation, and importantly radio frequency (RF) assemblies. In this paper, we present a multilayered material protection solution, a multilayered protection barrier, that mitigates the effects of AO and UV without disrupting the functional performance of tested assemblies. This multilayered protection barrier deposited via a custom-built plasma-enhanced chemical vapor deposition (PECVD) system is designed so as to deposit all necessary layers without breaking vacuum to maximize the adhesion to the surface of the substrate and to ensure no pinhole erosion is present. In the multilayer solution, a moisture and outgassing barrier (MOB) is coupled with an AO and UV capping layer to provide complete protection.

Ultra-broadband light trapping using nanotextured decoupled graphene multilayers.

The ability to engineer a thin two-dimensional surface for light trapping across an ultra-broad spectral range is central for an increasing number of applications including energy, optoelectronics, and spectroscopy. Although broadband light trapping has been obtained in tall structures of carbon nanotubes with millimeter-tall dimensions, obtaining such broadband light-trapping behavior from nanometer-scale absorbers remains elusive. We report a method for trapping the optical field coincident with few-layer decoupled graphene using field localization within a disordered distribution of subwavelength-sized nanotexturing metal particles. We show that the combination of the broadband light-coupling effect from the disordered nanotexture combined with the natural thinness and remarkably high and wavelength-independent absorption of graphene results in an ultrathin (15 nm thin) yet ultra-broadband blackbody absorber, featuring 99% absorption spanning from the mid-infrared to the ultraviolet. We demonstrate the utility of our approach to produce the blackbody absorber on delicate opto-microelectromechanical infrared emitters, using a low-temperature, noncontact fabrication method, which is also large-area compatible. This development may pave a way to new fabrication methodologies for optical devices requiring light management at the nanoscale.

Optical nanostructures in 2D for wide-diameter and broadband beam collimation.

Eliminating curved refracting lensing components used in conventional projection, imaging and sensing optical assemblies, is critical to enable compactness and miniaturisation of optical devices. A suitable means is replacing refracting lenses with two-dimensional optical media in flat-slab form, to achieve an equivalent optical result. One approach, which has been the focus of intense research, uses a Veselago lens which features a negative-index metamaterial. However, practical implementations rely on resonance techniques, thus broadband operation at optical frequencies imposes significant technical challenges that have been difficult to overcome. Here, we demonstrate a highly-collimated, broadband, wide-diameter beam from a compact source in flat-slab form, based on light collimation using nanomaterials ordered in patterns and embedded into flexible polymers. These provide a highly anisotropic absorption coefficient due to patterns created by vertical carbon nanotube structures grown on glass, and the anisotropic electrical conductivity of the nanotubes. We show this nanostructure strongly absorbs unwanted off-axis light rays, whilst transmitting the desired on-axis rays, to achieve the required optical effect over broadband, from visible to short-infrared, thus circumventing some technical limitations of negative-index metamaterials. We further show a low substrate-temperature system for nanotube growth, allowing direct implementation into heat-sensitive large-area devices.

Efficient coupling of optical energy for rapid catalyzed nanomaterial growth: high-quality carbon nanotube synthesis at low substrate temperatures.

The synthesis of high-quality nanomaterials depends on the efficiency of the catalyst and the growth temperature. To produce high-quality material, high-growth temperatures (often up to 1000 °C) are regularly required and this can limit possible applications, especially where temperature sensitive substrates or tight thermal budgets are present. In this study, we show that high-quality catalyzed nanomaterial growth at low substrate temperatures is possible by efficient coupling of energy directly into the catalyst particles by an optical method. We demonstrate that using this photothermal-based chemical vapor deposition method that rapid growth (under 4 min, which includes catalyst pretreatment time) of high-density carbon nanotubes can be grown at substrate temperatures as low as 415 °C with proper catalyst heat treatment. The growth process results in nanotubes that are high quality, as judged by a range of structural, Raman, and electrical characterization techniques, and are compatible with the requirements for interconnect technology.