Graded Composite Architecture for Thermal Management

Design and fabrication of a high thermal conductivity carbon fiber/aluminum matrix composite architecture is proposed which consists of discrete segments of functional areas that can respond to complex design calling for thermal management, low-expansion, structural, and low specific weight requirements. Composites will be produced utilizing Hollow and Planar Cathode Magnetron Sputtering Processing, by depositing a coating of the aluminum matrix material onto continuous and discontinuous graphite fibers (K up to 3000 W/mK), including interfacial layers to assure fiber/matrix bonding and suppression of adverse interface reactions. Coated fibers will be hot consolidated into quasi-isotropic composites. Compliance with varying functional requirements (e.g.,high thermal conductivity versus high tensile strength and expansion control) can be accomplished by varying type and fiber/matrix volume ratios. Basic modeling of thermal conductivity, strength, and CTE will be performed and confirmed by analytical examination on composite samples. Providing novel material for thermal management applications in space platforms while performing structural functions at low specific weights. The same requirement profile has been identified for thermal management components in military and civilian electronics and power plants, as well as for energy storage (electrical batteries and hydrogen fuel tanks) for alternative fuel concepts for automobiles.