Abstract: Methods of making a graphitic carbon-carbon composite from thermosetting polymer resin include (a) infusing bis-Schiff base resin into a carbon fiber reinforcement to form an uncured resin embedded composite, (b) positioning the uncured resin embedded composite on a substrate under a vacuum enclosure, (c) curing the bis-Schiff base resin at a first elevated temperature under vacuum to form a polymer matrix composite, (d) heating the polymer matrix composite at a second elevated temperature under inert atmosphere to form a porous carbon-carbon composite, (e) re-infusing bis-Schiff base resin into the porous carbon-carbon composite and curing under vacuum at a third elevated temperature to generate a reinfused porous carbon-carbon composite, and (f) heating the reinfused porous carbon-carbon composite at a fourth elevated temperature under inert gas to form the graphitic carbon-carbon composite.

Abstract: Methods of producing a fiber reinforced polymer matrix composite and a composite thermal protection system formed from the same. The method includes forming a polymerized fiber reinforced composite which including a cured thermoset polymer matrix and at least one reinforcement material. The method further includes treating at least a portion of a first face of the polymerized fiber reinforced composite with electromagnetic radiation to raise the temperature of the portion of the first face to at least 800° C. to produce a surface layer of graphitized carbon and a bulk polymerized fiber reinforced composite representing the untreated polymerized fiber reinforced composite. Further, the surface layer of graphitized carbon has an electrical conductivity of 0.25 S m?1 to 2.5 S m?1 where the electrical conductivity and a thermal conductivity are both greater than those of the bulk polymerized reinforced composite.