Abstract
Mass gain in the aerospace sector is highly demandable for energy savings and operational efficiency. Replacement of metal parts by polymer composites meets this prerequisite, provided the targeted functional properties are recovered. In the present contribution, we propose two innovative and scalable processes for the metallization of the internal faces of carbon fiber reinforced polymer radiofrequency waveguides foreseen for implementation in telecommunications satellites. They involve sequential direct liquid injection metalorganic chemical vapor deposition of copper and cobalt. The use of ozone pretreatment of the polymer surface prior deposition, or of cost effective anhydrous dimethoxyethane as solvent for the injection of the copper precursor, yield strongly adherent, 5 µm Cu films on the polymer composite. Their electrical resistivity is in the 4.1–5.0 μΩ·cm range, and they sustain thermal cycling between −175 °C and +170 °C. Such homogeneous and conformal films can be obtained at temperatures as low as 115 °C. Demonstration is achieved on a polymer composite waveguide, composed of metallized 60-mm long straight sections and of E-plane and H-plane elbows, that paves the way towards the metallization of scale one devices.
Highlights
Engineering Copper Adhesion on Keywords: thin films and coatings; space components; chemical vapor deposition; polymer composites
We demonstrate that the direct liquid injection (DLI)-MOCVD process is technologically more viable due to its simplicity and lower cost as compared with other DLI-MOCVD processes
In order to better understand their respective effect on the surface, we perform wettability measurements on untreated, O3 pretreated, and a substrate exposed to the DME solvent for 45 min in deposition conditions (195 ◦ C, 5 Torr) without precursor
Summary
Engineering Copper Adhesion on Keywords: thin films and coatings; space components; chemical vapor deposition; polymer composites. Carbon fiber reinforced polymers (CFRP) offer mass reduction and superior thermal mechanical properties, they are attractive alternatives to aluminum or titanium alloys [1,2] This is the case in the space sector, which critically relays on the production of ultra-strong and ultra-light structural and functional components [3]. Compared with Al, the density of CFRPs is significantly lower, their stiffness is three times higher and their thermal expansion is significantly lower These three properties are critical for embedded parts in satellites, and for this reason radiofrequency (RF) waveguides in telecommunication satellites that are made of Al can be redesigned with CFRP composites. Publisher’s Note: MDPI stays neutral with regard to jurisdictional claims in published maps and institutional affiliations
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