Consolidation of reactive Ultem® powder-coated carbon fiber tow for space structure composites by resistive heating

In this exploratory study, polyacrylonitrile (PAN)-based carbon fiber tows are coated with a commercial, heat-crosslinkable polyetherimide (Ultem(R)) powder. Then an electrical current is applied across the powder-coated fiber tows (towpreg) to melt the thermoplastic powder and form rigidized composites. These consolidated composite samples are characterized by scanning electron microscopy (SEM) and conventional tensile testing. Measuring the applied current and the degree of consolidation yielded the power requirement for successful wetting of the carbon fiber tows by Ultem melt, both on earth and in outer space. The results show that resistive heating is a feasible route for the rigidization of inflatable composite structures in space.