Review and Experimental Update on Manufacturing of Hybrid Carbon Fiber Composites for Space Use

Hybrid materials have multifunctional capabilities that are particularly attractive for space applications in order to overcome issues related to the harshness of the environment, especially during long-duration missions. Hybridization is traditionally carried out by mixing reinforcements of different natures, such as carbon with glass/kevlar fibers, or by integrating nanomaterials into the composite structure. Promising results in terms of improved toughness, ductility, and damping ability have been recorded by placing a thermoplastic interlayer between adjacent thermosetting plies reinforced with carbon fibers. These hybrid materials have additional functionalities such as thermoformability and repairability, which make them suitable for several industrial applications. In this work, a literature review on hybrid composites is presented and experimental results on the manufacturing of hybrid carbon fiber epoxy/PEEK laminates are reported. Thermoplastic films of 25 μm and 200 μm thickness have been used as well as two manufacturing procedures. The high-thickness interlayer laminate, that was compression-molded at 250 °C, showed the highest mechanical properties with a bending strength of 340 MPa and an elastic moules of 50 GPa. The other composite, that was molded at 350 °C, exhibited reduced mechanical properties.