Abstract: A method of fabricating complex hollow composite structures from laminates of fiber reinforced synthetic resins. The structures are fully monocoque tubes with no seams. The tubes are manufactured by wrapping a hollow semi-rigid inner mandrel made of thermoplastic material such as polystyrene or ABS (acrylonitrile-butadiene-styrene co-polymer) with layers of composite sheets. The sheets are made from high-strength fibers impregnated with thermosetting or thermoplastic resins.The laminated mandrel is placed in a mold, heated and inflated to a predetermined pressure. The pressure can range from 20-200 psig and even higher, while the curing temperature can range from 200.degree.-600.degree. F. The pressure generated by the expanding core produces a highly consolidated composite structure that has fewer voids, a more uniform thickness, and an increased fiber content compared to hollow composites made by other fabrication methods.

Abstract: A carbon-carbon mirror for high thermal input space applications is comprised of a plurality of thermally conductive, metallic layers formed as a laminate structure atop a carbon-carbon substrate. Within the laminate structure, a first thin adhesion layer of chromium is formed directly on the surface of a carbon-carbon substrate. Atop the adhesion layer, a plating base layer of gold or copper is deposited, followed by a thick working/smnoothing layer of nickel, which serves as the optically reflective surface of the mirror. The nickel layer is polished to a precision flatness or smoothness. Because the underlying gold and chromium layers possess high thermal conductivity, they enhance the transmission of heat from the cladding layer to the underlying carbon-carbon substrate, thereby preventing the laminate from absorbing heat, which would lead to delamination of the structure.