Liquid phase deposition of a space-durable, antistatic SnO₂ coating on Kapton

Activation of polyimide by oxygen plasma for atomic layer deposition of highly compact titanium oxide coating

Titanium oxide (TiO2) coated polyimide has broad application prospects under extreme conditions. In order to obtain a high-quality ultra-thin TiO2coating on polyimide by atomic layer deposition (ALD), the polyimide was activated byin situoxygen plasma. It was found that a large number of polar oxygen functional groups, such as carboxyl, were generated on the surface of the activated polyimide, which can significantly promote the preparation of TiO2coating by ALD. The nucleation and growth of TiO2were studied by x-ray photoelectron spectroscopy monitoring and scanning electron microscopy observation. On the polyimide activated by oxygen plasma, the size of TiO2nuclei decreased and the quantity of TiO2nuclei increased, resulting in the growth of a highly uniform and dense TiO2coating. This coating exhibited excellent resistance to atomic oxygen. When exposed to 3.5 × 1021atom cm-2atomic oxygen flux, the erosion yield of the polyimide coated with 100 ALD cycles of TiO2was as low as 3.0 × 10-25cm3/atom, which is one order less than that of the standard POLYIMIDE-ref Kapton®film.

Reactive Molecular Dynamics Study of the Mechanism and Effect of Various Protective Coatings on the Protection of Polyimide Antierosion from Atomic Oxygen

Polyimide (PI), due to its exceptional performance, is commonly utilized in spacecraft. However, when such polymers are used in spacecraft navigating low Earth orbit, they are exposed to atomic oxygen (AO) that can cause the polymer to decompose. A protective coating method is a more effective way to safeguard the polymer from erosion caused by AO. This study employs the molecular dynamics simulation based on the reaction force field to investigate the protective effects of various coatings, including polydimethylsiloxane (PDMS), graphene (Gr), polytetrafluoroethylene (PTFE), and the (0 0 1), (0 1 1), and (1 1 1) surfaces of SiO2. The results indicate that the protective performance of the (0 1 1) surface is superior to that of the (0 0 1) and (1 1 1) surfaces. Moreover, protective coatings are classified into three categories based on different protective mechanisms: rebound, absorption, and sacrificial. The protective effectiveness of coatings depends on their anti-AO performance and ability to combine with the substrate. Gr displays exceptional anti-AO properties and can effectively shield the substrate from AO erosion. Silicone-based coatings have a superior ability to adhere to PI substrates, and PDMS is an excellent choice for protective coatings. This paper offers guidance for the protective coating method of PIs against AO erosion.

Carbon Nanocomposites in Aerospace Technology: A Way to Protect Low-Orbit Satellites

Recent advancements in space technology and reduced launching cost led companies, defence and government organisations to turn their attention to low Earth orbit (LEO) and very low Earth orbit (VLEO) satellites, for they offer significant advantages over other types of spacecraft and present an attractive solution for observation, communication and other tasks. However, keeping satellites in LEO and VLEO presents a unique set of challenges, in addition to those typically associated with exposure to space environment such as damage from space debris, thermal fluctuations, radiation and thermal management in vacuum. The structural and functional elements of LEO and especially VLEO satellites are significantly affected by residual atmosphere and, in particular, atomic oxygen (AO). At VLEO, the remaining atmosphere is dense enough to create significant drag and quicky de-orbit satellites; thus, thrusters are needed to keep them on a stable orbit. Atomic oxygen-induced material erosion is another key challenge to overcome during the design phase of LEO and VLEO spacecraft. This review covered the corrosion interactions between the satellites and the low orbit environment, and how it can be minimised through the use of carbon-based nanomaterials and their composites. The review also discussed key mechanisms and challenges underpinning material design and fabrication, and it outlined the current research in this area.

Research Progress and Application of Polyimide-Based Nanocomposites

Polyimide (PI) is one of the most dominant engineering plastics with excellent thermal, mechanical, chemical stability and dielectric performance. Further improving the versatility of PIs is of great significance, broadening their application prospects. Thus, integrating functional nanofillers can finely tune the individual characteristic to a certain extent as required by the function. Integrating the two complementary benefits, PI-based composites strongly expand applications, such as aerospace, microelectronic devices, separation membranes, catalysis, and sensors. Here, from the perspective of system science, the recent studies of PI-based composites for molecular design, manufacturing process, combination methods, and the relevant applications are reviewed, more relevantly on the mechanism underlying the phenomena. Additionally, a systematic summary of the current challenges and further directions for PI nanocomposites is presented. Hence, the review will pave the way for future studies.

Mechanically Robust Irradiation, Atomic Oxygen, and Static-Durable CrOx/CuNi Coatings on Kapton Serving as Space Station Solar Cell Arrays

The polymers that served for solar cell arrays are constantly subject to various hazards, such as atomic oxygen (AO), ion irradiation, or electrostatic discharge (ESD) events. To address these issues, we fabricated and sifted CrO_0.16/CuNi-coated Kapton with a gradient structure with the goal of reaching an equilibrium between AO durability and resistance. The resulting material exhibits an impressively low E_y of 6.61 × 10^-26 cm³ atom^-1, 2.20% of which was detected as pristine Kapton. Self-evolution of the CrO_0.16 coating under 525.4 displacement per atom (dpa) Fe⁺ ion irradiation indicated that it can still maintain a good state of ultrafine nanocrystalline in addition to local amorphization. Its AO-based degradation and irradiation evolution are demonstrated by molecular dynamics (MD) simulations. It is mechanically robust enough to endure the cyclic folding treatments attributed to its gradient structure fabrication. Moreover, the CrO_0.16/CuNi-coated Kapton exhibits alleviated electrostatic accumulation capability and sufficient conductivity. Our strategy has promising potential for creating surface protection on flexible polymers operating in the low Earth orbit (LEO).

Double-Layer Nacre-Inspired Polyimide-Mica Nanocomposite Films with Excellent Mechanical Stability for LEO Environmental Conditions

Owing to their outstanding comprehensive performance, polyimide (PI) composite films are widely used on the external surfaces of spacecraft to protect them from the adverse conditions of low Earth orbit (LEO). However, current PI composite films have inadequate mechanical properties and atomic oxygen (AO) resistance. Herein, this work fabricates a new PI-based nanocomposite film with greatly enhanced mechanical properties and AO resistance by integrating mica nanosheets with PI into a unique double-layer nacre-inspired structure with a much higher density of mica nanosheets in the top layer. In addition, the unique microstructure and the intrinsic properties of mica also impart the nanocomposite film with favorable ultraviolet and high-temperature resistance. The comprehensive performance of this material is superior to those of pure PI, single-layer PI-mica, and previously reported PI-based composite films. Thus, the double-layer nanocomposite film displays great potential as an aerospace material for use in LEO.

Atomic-Oxygen-Durable and Antistatic α-AlxTiyO/γ-NiCr Coating on Kapton for Aerospace Applications

Polymers used for the exteriors of spacecraft are always exposed to risks such as atomic oxygen (AO) or electrostatic discharge (ESD) degradation. In this work, an Al_xTi_yO/NiCr coating with excellent mechanical stability, AO durability, and electrostatic dissipative properties was deposited via ion implantation (IIP), filter cathode vacuum arc (FCVA), and high-power impulse magnetron sputtering (HiPIMS) on a flexible Kapton substrate. Scratch and cycle folding tests indicated good adhesion and toughness of the Al_xTi_yO/NiCr-coated Kapton, which were due to the gradient structure fabricated by the multitechnology combination. AO exposure tests demonstrated an extremely low erosion yield (E_y = 5.15 × 10^-26 cm³ atom^-1) of the Al_xTi_yO/NiCr-coated Kapton, only 1.72% of that observed for pristine Kapton. Moreover, Rutherford backscattering spectrometry (RBS) and Kelvin probe force microscopy (KPFM) results showed that the Al_xTi_yO/NiCr-coated Kapton has elevated surface electrostatic dissipative properties and sufficient conductivity. The multitechnology combination offers great flexibility for customizing the gradient structure to realize a comprehensive performance improvement. In addition, such a coating has great prospects for aerospace applications.

Flexible Hard Coatings with Self-Evolution Behavior in a Low Earth Orbit Environment

Lightweight, long lifetime, and flexible polymer membrane-based structures, which are tightly folded on the ground and then unfolded in space, suffer from repeated bending before launching and fatal erosion on exposure to atomic oxygen (AO) in a low Earth orbit (LEO). Although various AO-resistant coatings have been developed, a coating that can simultaneously meet the critical requirements for the mechanical robustness and long-term protection of polymer membranes is rare. Here, we fabricated a coating with mechanical robustness and long-term space endurance, starting from an inorganic polymer precursor. A hybrid coating with a nanoscale polymer/silica bicontinuous phase is first prepared on the ground, which exhibits outstanding flexibility and excellent abrasion resistance. Then, the coating shows an in situ self-evolution behavior under AO and ultraviolet (UV) synergism to afford dense and crack-free silica coating with outstanding endurance. Our strategy displays great potential for protecting deployable membrane structures serving in the LEO.

Transparent, Water-Repellent, Antiviral, Antistatic, and Flexible Cu-Plasma-Polymerized Fluorocarbon Nanocomposite Thin Films

Polymer thin films containing fluorine are attracting much attention in various high-tech industries owing to their transparency, flexibility, and excellent water repellency. However, the generation of static electricity due to high electrical resistance limits their application. In this study, highly transparent and flexible Cu-plasma-polymerized fluorocarbon (PPFC) nanocomposite thin films that exhibit hydrophobicity and antistatic properties are proposed. These films, obtained using the mid-range frequency sputtering, exhibited a light transmittance of 84.2%, a water contact angle of 94.6°, and a sheet resistance of 1.2 × 10¹² Ω/□. Transmission electron microscopy and small angle X-ray scattering confirmed that Cu nanoparticles with an average size of 4-5 nm were distributed uniformly in the PPFC matrix. In repeated fatigue bending tests, the Cu-PPFC nanocomposite thin films exhibited excellent mechanical robustness and flexibility. Antiviral properties of the Cu-PPFC nanocomposite thin films were evaluated against influenza A virus, and the number decreased by 96.9% after 30 min. Carbon nanotube-Cu-polytetrafluoroethylene composite targets are advantageous for large-area coating and mass production because they can be applied in large-area sputtering and roll-to-roll processes. The transparency, charging characteristics, and water repellency can be easily controlled in Cu-PPFC nanocomposite thin films by controlling the sputtering power density according to the required product. Therefore, these films can be applied in various industries such as flexible displays, medical, automobiles, functional textiles, and aerospace.

Graphene Coating for Enhancing the Atom Oxygen Erosion Resistance of Kapton

Atom oxygen (AO) can cause most spacecraft material erosion seriously. Liquid-exfoliated graphene by jet cavitation was used to coat Kapton employed on spacecraft to enhance its AO erosion resistance. The coating was prepared by vacuum filtering and transferring. After AO exposure, compared with naked Kapton, the mass loss of coated Kapton reduced to 3.73% and the erosion yield reduced to 3.67%. AO reacted with graphene and then was left in the coating. The coating was degenerated slightly, but still performed well. We believe that graphene coating could be potentially applied to increase the material’s life span on spacecraft.

Synthesis of UV-Responsive Self-Healing Microcapsules and Their Potential Application in Aerospace Coatings

Advanced polymer composite coatings in the spacecraft are threatened by harsh space environment factors, such as strong UV radiation, atomic oxygen, thermal cycles, space debris, etc. Their service life can be drastically shortened by the unavoidable formation of cracks caused by these factors (especially strong and abundant UV radiation) during long-term flight. Herein, a UV-responsive microcapsule-based coating is developed for in-orbit damage repairing. UV-responsive microcapsules of which the inner polymeric shell can be degraded rapidly by the outer pure TiO₂ shell under UV radiation are produced by UV-initiated polymerization of Pickering emulsions and subsequently embedded into silicon resin matrices. When damaged, some microcapsules will be ruptured under the stimulus of external force, afterward the unbroken ones around the scratched areas will be degraded by UV radiation, as a result, encapsulated healing agents can be released and finally repair cracks. In this system, UV-responsive microcapsules can release more agents more effectively due to the dual release mode, compared with the traditional crack-repairing system. Moreover, the damage of UV radiation in space can be transferred into the favorable ones, which makes it have a potential application in aerospace coatings.

Advances in Polyimide-Based Materials for Space Applications

The space environment raises many challenges for new materials development and ground characterization. These environmental hazards in space include solar radiation, energetic particles, vacuum, micrometeoroids and debris, and space plasma. In low Earth orbits, there is also a significant concentration of highly reactive atomic oxygen (AO). This Progress Report focuses on the development of space-durable polyimide (PI)-based materials and nanocomposites and their testing under simulated space environment. Commercial PIs suffer from AO-induced erosion and surface electric charging. Modified PIs and PI-based nanocomposites are developed and tested to resist degradation in space. The durability of PIs in AO is successfully increased by addition of polyhedral oligomeric silsesquioxane. Conductive materials are prepared based on composites of PI and either carbon nanotube (CNT) sheets or 3D-graphene structures. 3D PI structures, which can expand PI space applications, made by either additive manufacturing (AM) or thermoforming, are presented. The selection of AM-processable engineering polymers in general, and PIs in particular, is relatively limited. Here, innovative preliminary results of a PI-based material processed by the PolyJet technology are presented.

Hyperthermal atomic oxygen durable transparent silicon-reinforced polyimide

A clear poly(amic acid) was reinforced by a trisilanolphenyl polyhedral oligomeric silsesquioxane (POSS) by direct dissolution, and transparent silicon-reinforced polyimide (Si-RPI) films with different POSS loadings were obtained after curing, showing high transmittance of >90% within 380–800 nm. The Si-RPI films were exposed to a ground hyperthermal atomic oxygen (AO) beam. The erosion depths and derived erosion yields of the materials decreased with POSS loadings. At a 20 wt% POSS loading, the Si-RPI showed an erosion yield of 0.13 × 10−24 cm3 atom−1 at a fluence of 2.79 × 1020 O atoms cm−2. Surface morphology and element composition characterization on Si-RPI indicated that SiOx-based passivating layers were formed on surfaces upon the hyperthermal AO attack. This study suggests a facile way of reinforcing Si into transparent polyimide for a promising candidate of spacecraft coating material operating in low Earth orbit.

Mechanically Robust Atomic Oxygen-Resistant Coatings Capable of Autonomously Healing Damage in Low Earth Orbit Space Environment

Polymeric materials used in spacecraft require to be protected with an atomic oxygen (AO)-resistant layer because AO can degrade these polymers when spacecraft serves in low earth orbit (LEO) environment. However, mechanical damage on AO-resistant coatings can expose the underlying polymers to AO erosion, shortening their service life. In this study, the fabrication of durable AO-resistant coatings that are capable of autonomously healing mechanical damage under LEO environment is presented. The self-healing AO-resistant coatings are comprised of 2-ureido-4[1H]-pyrimidinone (UPy)-functionalized polyhedral oligomeric silsesquioxane (POSS) (denoted as UPy-POSS) that forms hydrogen-bonded three-dimensional supramolecular polymers. The UPy-POSS supramolecular polymers can be conveniently deposited on polyimides by a hot pressing process. The UPy-POSS polymeric coatings are mechanically robust, thermally stable, and transparent and have a strong adhesion toward polyimides to endure repeated bending/unbending treatments and thermal cycling. The UPy-POSS polymeric coatings exhibit excellent AO attack resistance because of the formation of epidermal SiO2 layer after AO exposure. Due to the reversibility of the quadruple hydrogen bonds between UPy motifs, the UPy-POSS polymeric coatings can rapidly heal mechanical damage such as cracks at 80 °C or under LEO environment to restore their original AO-resistant function.

Effects of hyperthermal atomic oxygen on a cyanate ester and its carbon fiber-reinforced composite

The durability of cyanate ester (CE) to hyperthermal atomic oxygen (AO) attack in low Earth orbit may be enhanced by the addition of carbon fiber to form a carbon fiber-reinforced cyanate ester composite (CFCE). To investigate the durability of CFCE relative to CE, samples were exposed to a pulsed hyperthermal AO beam in two distinct types of experiments. In one type of experiment, samples were exposed to the beam, with pre- and post-characterization of mass (microbalance), surface topography (scanning electron microscopy (SEM)), and surface chemistry (X-ray photoelectron spectroscopy (XPS)). In the second type of experiment, the beam was directed at a sample surface, and volatile products that scattered from the surface were detected in situ with the use of a rotatable mass spectrometer detector. CFCE exhibited less mass loss than pure CE with a given AO fluence, confirming that the incorporation of carbon fiber adds AO resistance to CE. Erosion yields of CE and CFCE were 2.63 ± 0.16 × 10−24 and 1.46 ± 0.08 × 10−24 cm3 O-atom−1, respectively. The reduced reactivity of CFCE in comparison to CE was manifested in less oxidation of the CFCE surface in XPS measurements and reduced CO, CO2, and OH reaction products in beam-surface scattering experiments. The surface topographical images collected by SEM implied different surface deterioration processes for CE and CFCE. A change of surface topography with increasing AO fluence for CE indicated a threshold AO fluence, above which the erosion mechanism changed qualitatively. CFCE showed almost intact carbon fibers after relatively low AO fluences, and while the fibers eventually eroded, they did not erode as rapidly as the CE component of the composite.

Universal Nature-Inspired Coatings for Preparing Noncharging Surfaces

Static charge generated by contact electrification on surfaces can lead to many undesirable consequences such as a reduction in the efficiency of manufacturing processes, damage to equipment, and explosions. However, it is extremely challenging to avoid contact electrification because it is ubiquitous: almost all types of materials charge on contact. Here, we coated materials with naturally occurring polydopamine (PDA) and tannic acid (TA) for preparing noncharging surfaces. Importantly, these coatings are very versatile and can be coated on a wide range of materials, including metals, inorganic materials, semiconductors, and polymers. Once coated, the amount of charge generated was found to reduce dramatically at different humidities. The reduction in charge may be due to the radical-scavenging property of PDA and TA. This simple general approach is ideal for coating the vast variety of materials that need to resist charging by contact electrification.

Resistance of POSS Polyimide Blends to Hyperthermal Atomic Oxygen Attack

Copolymers of polyhedral oligomeric silsesquioxane (POSS) and polyimide (PI) have shown remarkable resistance to atomic oxygen (AO) attack and have been proposed as replacements for Kapton on the external surfaces of spacecraft in the harsh oxidizing environment of low Earth orbit (LEO). POSS PI blends would be an economical alternative to the copolymers if they also resisted AO attack. Thus, blends of trisilanolphenyl (TSP) POSS and PI with different weight percentages of the Si₇O₉ POSS cage were cast into films and exposed to a hyperthermal AO beam, and they were characterized in terms of their recession, mass loss, surface morphology, and surface chemistry. In order to compare the AO resistance of the blends with POSS PI copolymers, samples of previously studied copolymers were also investigated in parallel with the blends. For all POSS PI materials, the AO resistance increased with increasing AO fluence and with increasing POSS cage loading. At similar POSS cage loadings and exposure conditions, the TSP POSS PI blends showed comparable erosion yields to the POSS PI copolymers, with specific samples of blends and copolymers achieving erosion yields as low as 0.066 × 10^-24 cm³ atom^-1 with an AO fluence of 5.93 × 10²⁰ O atoms cm^-2. SEM and XPS analyses indicated that passivating SiO_x layers were formed on the surfaces of all POSS-containing polymers during AO exposure. Thus, a TSP POSS PI blend is proposed as a low-cost variant of a POSS polyimide for use in extreme oxidizing environments, such as LEO.

Atomic-Oxygen-Durable and Electrically-Conductive CNT-POSS-Polyimide Flexible Films for Space Applications

In low Earth orbit (LEO), hazards such as atomic oxygen (AO) or electrostatic discharge (ESD) degrade polymeric materials, specifically, the extensively used polyimide (PI) Kapton. We prepared PI-based nanocomposite films that show both AO durability and ESD protection by incorporating polyhedral oligomeric silsesquioxane (POSS) and carbon nanotube (CNT) additives. The unique methods that are reported prevent CNT agglomeration and degradation of the CNT properties that are common in dispersion-based processes. The influence of the POSS content on the electrical, mechanical, and thermo-optical properties of the CNT-POSS-PI films was investigated and compared to those of control PI and CNT-PI films. CNT-POSS-PI films with 5 and 15 wt % POSS content exhibited sheet resistivities as low as 200 Ω/□, and these resistivities remained essentially unchanged after exposure to AO with a fluence of ∼2.3 × 10(20) O atoms cm(-2). CNT-POSS-PI films with 15 wt % POSS content exhibited an erosion yield of 4.8 × 10(-25) cm(3) O atom(-1) under 2.3 × 10(20) O atoms cm(-2) AO fluence, roughly one order of magnitude lower than that of pure PI films. The durability of the conductivity of the composite films was demonstrated by rolling film samples with a tight radius up to 300 times. The stability of the films to thermal cycling and ionizing radiation was also demonstrated. These properties make the prepared CNT-POSS-PI films with 15 wt % POSS content excellent candidates for applications where AO durability and electrical conductivity are required for flexible and thermally stable materials. Hence, they are suggested here for LEO applications such as the outer layers of spacecraft thermal blankets.