A method of making a coated polymer-matrix composite (PMC) having high-temperature oxidation protection includes bonding a first surface of a flexible sublayer that is free of water to a first surface of a dry PMC substrate having a first coefficient of thermal expansion. The flexible sublayer inclu
A method of making a coated polymer-matrix composite (PMC) having high-temperature oxidation protection includes bonding a first surface of a flexible sublayer that is free of water to a first surface of a dry PMC substrate having a first coefficient of thermal expansion. The flexible sublayer includes an electrically conductive material in an effective amount to enable electrical conductivity of the flexible sublayer, and includes a low-modulus-of-elasticity material. The method includes heating the bonded flexible sublayer and the PMC substrate, and bonding a first surface of an oxygen-impervious, dense barrier-coating layer to a second surface of the flexible sublayer to form the coated PMC having high-temperature oxidation protection. The dense barrier-coating layer includes metallic materials and ceramic materials, each having a respective second coefficient of thermal expansion, and flexibility of the flexible sublayer protects the respective bonds when the first and second coefficients of thermal expansion are unequal.
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1. A method of making a coated polymer-matrix composite (PMC) having high-temperature oxidation protection, the method comprising the steps of: bonding a first surface of a flexible sublayer that is free of water to a first surface of a dry polymer-matrix composite (PMC) substrate having a first coe
1. A method of making a coated polymer-matrix composite (PMC) having high-temperature oxidation protection, the method comprising the steps of: bonding a first surface of a flexible sublayer that is free of water to a first surface of a dry polymer-matrix composite (PMC) substrate having a first coefficient of thermal expansion, wherein the flexible sublayer includes an electrically conductive material in an effective amount to enable electrical conductivity of the flexible sublayer, and further wherein the flexible sublayer includes a low-modulus-of-elasticity material selected from the group consisting of elastomers, silicones, silanes, siloxanes, and silazanes;heating the bonded flexible sublayer and the PMC substrate;bonding a first surface of an oxygen-impervious, dense barrier-coating layer to a second surface of the flexible sublayer to form the coated polymer-matrix composite (PMC) having high-temperature oxidation protection, wherein the oxygen-impervious, dense barrier-coating layer is selected from the group consisting of metallic materials and ceramic materials, each having a respective second coefficient of thermal expansion, and further wherein flexibility of the flexible sublayer protects the respective bonds when the first and second coefficients of thermal expansion are unequal; andbonding one or more additional oxygen-impervious, dense barrier-coating layers to a second surface of the oxygen-impervious, dense barrier-coating layer. 2. The method of claim 1 wherein the steps of bonding the first surface of the flexible sublayer and bonding the first surface of the oxygen-impervious, dense barrier-coating layer are performed using a process selected from the group consisting of electrodeposition, vacuum deposition, chemical deposition, vapor deposition and plasma spraying. 3. The method of claim 2 wherein the steps of bonding the first surface of the flexible sublayer and bonding the first surface of the oxygen-impervious, dense barrier-coating layer are performed using electrodeposition. 4. The method of claim 1 further comprising the step of reducing or eliminating degradation of the PMC substrate by the flexible sublayer reducing or eliminating strain mismatch between the PMC substrate and the oxygen-impervious, dense barrier-coating layer bonded to the second surface of the flexible sublayer. 5. The method of claim 1 further comprising before the step of bonding the first surface of the flexible sublayer, the step of treating the first surface of the PMC substrate with a treatment selected from the group consisting of chemical etching, abrading, and functionalizing, to optimize bonding reactivity with the first surface of the flexible sublayer. 6. The method of claim 1 further comprising before the step of bonding the first surface of the oxygen-impervious, dense barrier-coating layer, the step of treating the second surface of the flexible sublayer with a treatment selected from the group consisting of chemical etching, abrading, and functionalizing, to optimize bonding reactivity with the first surface of the oxygen-impervious, dense barrier-coating layer. 7. The method of claim 1 wherein the step of bonding the first surface of the flexible sublayer comprises bonding the first surface of the flexible sublayer including at least one electrically conductive material selected from the group consisting of carbon black, carbon nanofibers, carbon nanotubes, metallic whiskers, and metallic materials. 8. The method of claim 1 wherein the step of bonding the first surface of the flexible sublayer to the first surface of the dry polymer-matrix composite (PMC) substrate comprises bonding the first surface of the flexible sublayer to the first surface of the dry PMC substrate comprising a material selected from the group consisting of a polyimide HTPMC (high-temperature polymer-matrix composite), a bismaleimide HTPMC (high-temperature polymer-matrix composite), polybenzoxazole, polybenzoxazine, and polyetheretherketone. 9. The method of claim 1 wherein the step of heating the bonded flexible sublayer and the PMC substrate comprises heating the bonded flexible sublayer and the PMC substrate at an effective temperature for a sufficient period of time to remove any moisture to prevent volatilization of the moisture into superheated steam during operation and to prevent any debonding and delamination of the coated polymer-matrix composite (PMC). 10. The method of claim 1 wherein the step of bonding the first surface of the oxygen-impervious, dense barrier-coating layer comprises bonding the first surface of the oxygen-impervious, dense barrier-coating layer consisting of metallic materials selected from the group consisting of nickel, titanium, and alloys thereof. 11. A method of preparing a dense barrier-coating system for use with a dry polymer-matrix composite (PMC) substrate having a first coefficient of thermal expansion, the method comprising the steps of: bonding a first surface of a flexible sublayer that is free of water to a first surface of the dry polymer-matrix composite (PMC) substrate having the first coefficient of thermal expansion, wherein the flexible sublayer includes an electrically conductive material in an effective amount to enable electrical conductivity of the flexible sublayer, and further wherein the flexible sublayer includes a low-modulus-of-elasticity material selected from the group consisting of elastomers, silicones, silanes, siloxanes, and silazanes;heating the bonded flexible sublayer and the PMC substrate;bonding a first surface of an oxygen-impervious, dense barrier-coating layer to a second surface of the flexible sublayer such that the flexible sublayer is an intermediate layer between the oxygen-impervious, dense barrier-coating layer and the PMC substrate, and wherein the oxygen-impervious, dense barrier-coating layer is selected from the group consisting of metallic materials and ceramic materials, each having a respective second coefficient of thermal expansion, and further wherein flexibility of the flexible sublayer protects the respective bonds when the first and second coefficients of thermal expansion are unequal; and,bonding one or more additional oxygen-impervious, dense barrier-coating layers to a second surface of the oxygen-impervious, dense barrier-coating layer to form the dense barrier-coating system,wherein the dense barrier-coating system provides high-temperature oxidation protection of the PMC substrate at a temperature in a range of from about 350 degrees Fahrenheit to about 700 degrees Fahrenheit to extend a lifetime of the PMC from between about 1000 hours to about 15,000 hours. 12. The method of claim 11 further comprising before the step of bonding the first surface of the flexible sublayer, the step of treating the first surface of the PMC substrate with a treatment selected from the group consisting of chemical etching, abrading, and functionalizing, to optimize bonding reactivity with the first surface of the flexible sublayer. 13. The method of claim 11 further comprising before the step of bonding the first surface of the oxygen-impervious, dense barrier-coating layer, the step of treating the second surface of the flexible sublayer with a treatment selected from the group consisting of chemical etching, abrading, and functionalizing, to optimize bonding reactivity with the first surface of the oxygen-impervious, dense barrier-coating layer. 14. The method of claim 11 wherein the steps of bonding the first surface of the flexible sublayer and bonding the first surface of the oxygen-impervious, dense barrier-coating layer are performed using a process selected from the group consisting of electrodeposition, vacuum deposition, chemical deposition, vapor deposition and plasma spraying. 15. The method of claim 11 wherein the step of bonding the first surface of the flexible sublayer comprises bonding the first surface of the flexible sublayer including at least one electrically conductive material selected from the group consisting of carbon black, carbon nanofibers, carbon nanotubes, metallic whiskers and metallic materials. 16. The method of claim 11 further comprising the step of reducing or eliminating degradation of the PMC substrate by the flexible sublayer reducing or eliminating strain mismatch between the PMC substrate and the oxygen-impervious, dense barrier-coating layer bonded to the second surface of the flexible sublayer. 17. A method of reducing or eliminating degradation of a dry polymer-matrix composite (PMC) substrate having a first coefficient of thermal expansion, the method comprising the steps of: preparing a dense barrier-coating system for use with the dry PMC substrate having the first coefficient of thermal expansion, the steps of preparing comprising: bonding a first surface of a flexible sublayer that is free of water to a first surface of the dry PMC substrate having the first coefficient of thermal expansion, wherein the flexible sublayer includes an electrically conductive material in an effective amount to enable electrical conductivity of the flexible sublayer, and further wherein the flexible sublayer includes a low-modulus-of-elasticity material selected from the group consisting of elastomers, silicones, silanes, siloxanes, and silazanes;heating the bonded flexible sublayer and the PMC substrate;bonding a first surface of an oxygen-impervious, dense barrier-coating layer to a second surface of the flexible sublayer such that the flexible sublayer is an intermediate layer between the oxygen-impervious, dense barrier-coating layer and the PMC substrate, and wherein the oxygen-impervious, dense barrier-coating layer is selected from the group consisting of metallic materials and ceramic materials, each having a respective second coefficient of thermal expansion, and further wherein flexibility of the flexible sublayer protects the respective bonds when the first and second coefficients of thermal expansion are unequal; and,bonding one or more additional oxygen-impervious, dense barrier-coating layers to a second surface of the oxygen-impervious, dense barrier-coating layer to form the dense barrier-coating system,using the flexible sublayer to reduce or eliminate strain mismatch between the PMC substrate and the oxygen-impervious, dense barrier-coating layer bonded to the second surface of the flexible sublayer, and reducing or eliminating degradation of the dry PMC substrate. 18. The method of claim 17 wherein the step of preparing the dense barrier-coating system for use with the dry PMC substrate having the first coefficient of thermal expansion comprises preparing an aircraft dense-barrier coating system. 19. The method of claim 17 wherein the step of preparing the dense barrier-coating system for use with the dry PMC substrate having the first coefficient of thermal expansion comprises preparing the dense barrier-coating system to provide high-temperature oxidation protection of the PMC substrate at a temperature in a range of from about 350 degrees Fahrenheit to about 700 degrees Fahrenheit to extend a lifetime of the PMC from between about 1000 hours to about 15,000 hours. 20. The method of claim 17 wherein the steps of bonding the first surface of the flexible sublayer and bonding the first surface of the oxygen-impervious, dense barrier-coating layer are performed using a process selected from the group consisting of electrodeposition, vacuum deposition, chemical deposition, vapor deposition and plasma spraying.
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